EP2539295A2 - Heat-insulating refractory high-temperature resistant molded article - Google Patents
Heat-insulating refractory high-temperature resistant molded articleInfo
- Publication number
- EP2539295A2 EP2539295A2 EP11709864A EP11709864A EP2539295A2 EP 2539295 A2 EP2539295 A2 EP 2539295A2 EP 11709864 A EP11709864 A EP 11709864A EP 11709864 A EP11709864 A EP 11709864A EP 2539295 A2 EP2539295 A2 EP 2539295A2
- Authority
- EP
- European Patent Office
- Prior art keywords
- fibers
- weight
- silica
- binder
- cenospheres
- 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.)
- Ceased
Links
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims abstract description 58
- 239000000835 fiber Substances 0.000 claims abstract description 39
- 239000011230 binding agent Substances 0.000 claims abstract description 31
- 239000011435 rock Substances 0.000 claims abstract description 20
- 239000000377 silicon dioxide Substances 0.000 claims abstract description 20
- 239000000945 filler Substances 0.000 claims abstract description 16
- 239000010881 fly ash Substances 0.000 claims abstract description 16
- 239000010456 wollastonite Substances 0.000 claims abstract description 11
- 229910052882 wollastonite Inorganic materials 0.000 claims abstract description 11
- 239000007795 chemical reaction product Substances 0.000 claims abstract description 6
- 239000000203 mixture Substances 0.000 claims description 28
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 claims description 19
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 18
- 239000000919 ceramic Substances 0.000 claims description 16
- 238000000465 moulding Methods 0.000 claims description 16
- 239000005995 Aluminium silicate Substances 0.000 claims description 14
- 235000012211 aluminium silicate Nutrition 0.000 claims description 14
- 239000011449 brick Substances 0.000 claims description 12
- 229920003023 plastic Polymers 0.000 claims description 12
- 239000004033 plastic Substances 0.000 claims description 12
- 238000002844 melting Methods 0.000 claims description 11
- 239000002245 particle Substances 0.000 claims description 11
- 229910052593 corundum Inorganic materials 0.000 claims description 8
- 239000010431 corundum Substances 0.000 claims description 8
- 238000001035 drying Methods 0.000 claims description 8
- 230000004907 flux Effects 0.000 claims description 8
- 229920000642 polymer Polymers 0.000 claims description 8
- RMAQACBXLXPBSY-UHFFFAOYSA-N silicic acid Chemical compound O[Si](O)(O)O RMAQACBXLXPBSY-UHFFFAOYSA-N 0.000 claims description 7
- 229910052622 kaolinite Inorganic materials 0.000 claims description 5
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 claims description 5
- 229910010271 silicon carbide Inorganic materials 0.000 claims description 5
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 4
- 239000000654 additive Substances 0.000 claims description 4
- 229910052799 carbon Inorganic materials 0.000 claims description 4
- 238000010304 firing Methods 0.000 claims description 4
- 238000009413 insulation Methods 0.000 claims description 4
- 239000004575 stone Substances 0.000 claims description 4
- VVQNEPGJFQJSBK-UHFFFAOYSA-N Methyl methacrylate Chemical compound COC(=O)C(C)=C VVQNEPGJFQJSBK-UHFFFAOYSA-N 0.000 claims description 2
- BLRPTPMANUNPDV-UHFFFAOYSA-N Silane Chemical compound [SiH4] BLRPTPMANUNPDV-UHFFFAOYSA-N 0.000 claims description 2
- 239000002956 ash Substances 0.000 claims description 2
- CQEYYJKEWSMYFG-UHFFFAOYSA-N butyl acrylate Chemical compound CCCCOC(=O)C=C CQEYYJKEWSMYFG-UHFFFAOYSA-N 0.000 claims description 2
- 238000010276 construction Methods 0.000 claims description 2
- 229910000077 silane Inorganic materials 0.000 claims description 2
- 229910001338 liquidmetal Inorganic materials 0.000 claims 3
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 claims 2
- 238000001029 thermal curing Methods 0.000 claims 2
- NIXOWILDQLNWCW-UHFFFAOYSA-M Acrylate Chemical compound [O-]C(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-M 0.000 claims 1
- 229920000620 organic polymer Polymers 0.000 claims 1
- 229910052573 porcelain Inorganic materials 0.000 claims 1
- 239000000080 wetting agent Substances 0.000 claims 1
- 235000012239 silicon dioxide Nutrition 0.000 abstract description 5
- 239000003795 chemical substances by application Substances 0.000 abstract 1
- 238000000034 method Methods 0.000 description 14
- 229910052500 inorganic mineral Inorganic materials 0.000 description 13
- 239000011707 mineral Substances 0.000 description 13
- 238000005266 casting Methods 0.000 description 12
- SHFGJEQAOUMGJM-UHFFFAOYSA-N dialuminum dipotassium disodium dioxosilane iron(3+) oxocalcium oxomagnesium oxygen(2-) Chemical compound [O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[Na+].[Na+].[Al+3].[Al+3].[K+].[K+].[Fe+3].[Fe+3].O=[Mg].O=[Ca].O=[Si]=O SHFGJEQAOUMGJM-UHFFFAOYSA-N 0.000 description 11
- 239000000047 product Substances 0.000 description 11
- 238000004519 manufacturing process Methods 0.000 description 9
- 229910052863 mullite Inorganic materials 0.000 description 9
- 235000019362 perlite Nutrition 0.000 description 9
- 230000008569 process Effects 0.000 description 9
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 8
- 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 description 7
- 239000010451 perlite Substances 0.000 description 7
- 239000000126 substance Substances 0.000 description 7
- 229920001169 thermoplastic Polymers 0.000 description 7
- 239000004416 thermosoftening plastic Substances 0.000 description 7
- 239000002994 raw material Substances 0.000 description 6
- 239000007787 solid Substances 0.000 description 6
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 5
- 239000000463 material Substances 0.000 description 5
- -1 polylactate (PLA) Substances 0.000 description 5
- YKTSYUJCYHOUJP-UHFFFAOYSA-N [O--].[Al+3].[Al+3].[O-][Si]([O-])([O-])[O-] Chemical compound [O--].[Al+3].[Al+3].[O-][Si]([O-])([O-])[O-] YKTSYUJCYHOUJP-UHFFFAOYSA-N 0.000 description 4
- 238000006243 chemical reaction Methods 0.000 description 4
- 239000008187 granular material Substances 0.000 description 4
- 230000008018 melting Effects 0.000 description 4
- 238000002156 mixing Methods 0.000 description 4
- 239000010453 quartz Substances 0.000 description 4
- 239000003832 thermite Substances 0.000 description 4
- 229920000049 Carbon (fiber) Polymers 0.000 description 3
- 229910052782 aluminium Inorganic materials 0.000 description 3
- 230000008901 benefit Effects 0.000 description 3
- 239000004917 carbon fiber Substances 0.000 description 3
- 239000003245 coal Substances 0.000 description 3
- 238000009826 distribution Methods 0.000 description 3
- 239000002360 explosive Substances 0.000 description 3
- 238000001125 extrusion Methods 0.000 description 3
- 239000007788 liquid Substances 0.000 description 3
- 238000000197 pyrolysis Methods 0.000 description 3
- 230000009467 reduction Effects 0.000 description 3
- 238000007711 solidification Methods 0.000 description 3
- 230000008023 solidification Effects 0.000 description 3
- 239000007858 starting material Substances 0.000 description 3
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 description 2
- 239000004696 Poly ether ether ketone Substances 0.000 description 2
- 239000004952 Polyamide Substances 0.000 description 2
- 239000004698 Polyethylene Substances 0.000 description 2
- 239000004743 Polypropylene Substances 0.000 description 2
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical group [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 2
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 2
- 239000004566 building material Substances 0.000 description 2
- 125000004432 carbon atom Chemical group C* 0.000 description 2
- 239000004567 concrete Substances 0.000 description 2
- 239000000470 constituent Substances 0.000 description 2
- 239000003546 flue gas Substances 0.000 description 2
- 238000009472 formulation Methods 0.000 description 2
- 239000000446 fuel Substances 0.000 description 2
- 239000003365 glass fiber Substances 0.000 description 2
- 229910052742 iron Inorganic materials 0.000 description 2
- 239000003077 lignite Substances 0.000 description 2
- 239000012778 molding material Substances 0.000 description 2
- 239000004570 mortar (masonry) Substances 0.000 description 2
- 239000001301 oxygen Substances 0.000 description 2
- 229910052760 oxygen Inorganic materials 0.000 description 2
- 229920003229 poly(methyl methacrylate) Polymers 0.000 description 2
- 229920002647 polyamide Polymers 0.000 description 2
- 229920002530 polyetherether ketone Polymers 0.000 description 2
- 229920000573 polyethylene Polymers 0.000 description 2
- 229920000139 polyethylene terephthalate Polymers 0.000 description 2
- 239000005020 polyethylene terephthalate Substances 0.000 description 2
- 239000004926 polymethyl methacrylate Substances 0.000 description 2
- 229920001155 polypropylene Polymers 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 238000006479 redox reaction Methods 0.000 description 2
- 239000011819 refractory material Substances 0.000 description 2
- 238000007493 shaping process Methods 0.000 description 2
- 238000007569 slipcasting Methods 0.000 description 2
- 229910052596 spinel Inorganic materials 0.000 description 2
- 239000011029 spinel Substances 0.000 description 2
- 229920002160 Celluloid Polymers 0.000 description 1
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 1
- 208000015943 Coeliac disease Diseases 0.000 description 1
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 1
- 206010061218 Inflammation Diseases 0.000 description 1
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- 229920000034 Plastomer Polymers 0.000 description 1
- 239000004793 Polystyrene Substances 0.000 description 1
- 229910004298 SiO 2 Inorganic materials 0.000 description 1
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- 239000002253 acid Substances 0.000 description 1
- 239000004676 acrylonitrile butadiene styrene Substances 0.000 description 1
- 230000004913 activation Effects 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 description 1
- INJRKJPEYSAMPD-UHFFFAOYSA-N aluminum;silicic acid;hydrate Chemical compound O.[Al].[Al].O[Si](O)(O)O INJRKJPEYSAMPD-UHFFFAOYSA-N 0.000 description 1
- 229910052849 andalusite Inorganic materials 0.000 description 1
- 238000000137 annealing Methods 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- 229910052785 arsenic Inorganic materials 0.000 description 1
- RQNWIZPPADIBDY-UHFFFAOYSA-N arsenic atom Chemical compound [As] RQNWIZPPADIBDY-UHFFFAOYSA-N 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- ZJRXSAYFZMGQFP-UHFFFAOYSA-N barium peroxide Chemical compound [Ba+2].[O-][O-] ZJRXSAYFZMGQFP-UHFFFAOYSA-N 0.000 description 1
- 239000011324 bead Substances 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 229910052810 boron oxide Inorganic materials 0.000 description 1
- ZFXVRMSLJDYJCH-UHFFFAOYSA-N calcium magnesium Chemical compound [Mg].[Ca] ZFXVRMSLJDYJCH-UHFFFAOYSA-N 0.000 description 1
- 239000011455 calcium-silicate brick Substances 0.000 description 1
- 230000001413 cellular effect Effects 0.000 description 1
- 239000004568 cement Substances 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 239000003638 chemical reducing agent Substances 0.000 description 1
- 239000004927 clay Substances 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 230000000295 complement effect Effects 0.000 description 1
- 239000011246 composite particle Substances 0.000 description 1
- 238000012790 confirmation Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 229910052906 cristobalite Inorganic materials 0.000 description 1
- 230000006735 deficit Effects 0.000 description 1
- 210000003298 dental enamel Anatomy 0.000 description 1
- JKWMSGQKBLHBQQ-UHFFFAOYSA-N diboron trioxide Chemical compound O=BOB=O JKWMSGQKBLHBQQ-UHFFFAOYSA-N 0.000 description 1
- 150000002013 dioxins Chemical class 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000010292 electrical insulation Methods 0.000 description 1
- 239000003344 environmental pollutant Substances 0.000 description 1
- 239000010433 feldspar Substances 0.000 description 1
- 238000005187 foaming Methods 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 239000000156 glass melt Substances 0.000 description 1
- 239000003292 glue Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 229910001385 heavy metal Inorganic materials 0.000 description 1
- 229930195733 hydrocarbon Natural products 0.000 description 1
- 150000002430 hydrocarbons Chemical class 0.000 description 1
- 229910052739 hydrogen Inorganic materials 0.000 description 1
- 239000001257 hydrogen Substances 0.000 description 1
- 230000005660 hydrophilic surface Effects 0.000 description 1
- 230000004054 inflammatory process Effects 0.000 description 1
- 238000001746 injection moulding Methods 0.000 description 1
- 229910010272 inorganic material Inorganic materials 0.000 description 1
- 239000011147 inorganic material Substances 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 230000003993 interaction Effects 0.000 description 1
- 239000011872 intimate mixture Substances 0.000 description 1
- LIKBJVNGSGBSGK-UHFFFAOYSA-N iron(3+);oxygen(2-) Chemical compound [O-2].[O-2].[O-2].[Fe+3].[Fe+3] LIKBJVNGSGBSGK-UHFFFAOYSA-N 0.000 description 1
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 description 1
- 238000000462 isostatic pressing Methods 0.000 description 1
- 239000010443 kyanite Substances 0.000 description 1
- 229910052850 kyanite Inorganic materials 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- 239000011777 magnesium Substances 0.000 description 1
- 239000000391 magnesium silicate Substances 0.000 description 1
- 235000012243 magnesium silicates Nutrition 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 229910044991 metal oxide Inorganic materials 0.000 description 1
- 150000004706 metal oxides Chemical class 0.000 description 1
- 239000004005 microsphere Substances 0.000 description 1
- 229910000510 noble metal Inorganic materials 0.000 description 1
- 239000005332 obsidian Substances 0.000 description 1
- 238000013021 overheating Methods 0.000 description 1
- RVTZCBVAJQQJTK-UHFFFAOYSA-N oxygen(2-);zirconium(4+) Chemical compound [O-2].[O-2].[Zr+4] RVTZCBVAJQQJTK-UHFFFAOYSA-N 0.000 description 1
- 238000012856 packing Methods 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 231100000614 poison Toxicity 0.000 description 1
- 231100000719 pollutant Toxicity 0.000 description 1
- 239000004417 polycarbonate Substances 0.000 description 1
- 229920000515 polycarbonate Polymers 0.000 description 1
- 239000012704 polymeric precursor Substances 0.000 description 1
- 239000004800 polyvinyl chloride Substances 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 239000002243 precursor Substances 0.000 description 1
- 230000009257 reactivity Effects 0.000 description 1
- 238000003303 reheating Methods 0.000 description 1
- 238000009877 rendering Methods 0.000 description 1
- 230000002441 reversible effect Effects 0.000 description 1
- 239000004576 sand Substances 0.000 description 1
- 238000001878 scanning electron micrograph Methods 0.000 description 1
- 150000004756 silanes Chemical class 0.000 description 1
- 229910052851 sillimanite Inorganic materials 0.000 description 1
- 238000005245 sintering Methods 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
- 238000009987 spinning Methods 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 238000005979 thermal decomposition reaction Methods 0.000 description 1
- 238000007669 thermal treatment Methods 0.000 description 1
- 239000003440 toxic substance Substances 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
- 238000013022 venting Methods 0.000 description 1
- 239000005335 volcanic glass Substances 0.000 description 1
- 238000004056 waste incineration Methods 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
- 229910001928 zirconium oxide 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
Classifications
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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
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/24—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing alkyl, ammonium or metal silicates; containing silica sols
-
- 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
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/003—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hybrid binders other than those of the polycarboxylate type
-
- 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
- C04B33/00—Clay-wares
- C04B33/02—Preparing or treating the raw materials individually or as batches
- C04B33/04—Clay; Kaolin
-
- 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
- C04B33/00—Clay-wares
- C04B33/02—Preparing or treating the raw materials individually or as batches
- C04B33/13—Compounding ingredients
- C04B33/1305—Organic 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
- C04B33/00—Clay-wares
- C04B33/02—Preparing or treating the raw materials individually or as batches
- C04B33/13—Compounding ingredients
- C04B33/131—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
- C04B33/00—Clay-wares
- C04B33/02—Preparing or treating the raw materials individually or as batches
- C04B33/13—Compounding ingredients
- C04B33/1315—Non-ceramic binders
-
- 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
- C04B33/00—Clay-wares
- C04B33/02—Preparing or treating the raw materials individually or as batches
- C04B33/13—Compounding ingredients
- C04B33/132—Waste materials; Refuse; Residues
- C04B33/135—Combustion residues, e.g. fly ash, incineration waste
- C04B33/1352—Fuel ashes, e.g. fly ash
-
- 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
- C04B33/00—Clay-wares
- C04B33/36—Reinforced clay-wares
-
- 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
- C04B35/62605—Treating the starting powders individually or as mixtures
- C04B35/62625—Wet mixtures
- C04B35/62635—Mixing details
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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
- C04B35/626—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
- C04B35/6269—Curing of mixtures
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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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
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Definitions
- the invention relates to a heat-insulating refractory high-temperature resistant molded part containing a plurality of lightweight fillers, a binder and fibers and / or wollastonite, for applications up to about 1600 ° C.
- lightweight fillers is to be understood here as high-melting mineral granules of low density, for example fly ash, expanded volcanic rocks, expanded perlite, etc.
- Refractory bricks are formed refractory products with a total porosity> 45% and an application temperature of at least 800 ° C.
- ASTM C 155-70 and DIN EN 1094 define the temperature at which the shrinkage of the material after 24 h or 12 h is not more than 2% and a maximum density.
- silicate bricks To divide lightweight refractory bricks, silicate bricks, zirconia and corundum light bricks. The greatest importance and spread comes to the aluminum silicate light bricks (chamotte and mullite bricks).
- alumina carrier For the production of raw materials based on A1 2 0 3 , Si0 2 and possibly CaO are used.
- alumina carrier are raw materials such as clay, kaolin, chamotte,
- Sillimanite, andalusite, kyanite and mullite and alumina, alumina hydrate and corundum used.
- fine-grained raw materials In addition to the fine-grained raw materials, coarse-grained, porous raw materials such as lightweight chamotte and hollow spheres made from corundum and mullite are also used.
- Known refractory bricks have a bulk density of 0.5 to 1.4 g / cm 3 , a
- German Offenlegungsschrift DE 10 2007 012 489 A1 describes exclusively insulating and exothermic feeders from the foundry industry.
- Chapter 1 is a term from the foundry industry and refers to geometric sprues on castings, in the form of the voids volume deficit is to be placed during the casting solidification and which are removed in the cleaning process of the castings again.
- the feeders themselves are destroyed in this process (disposable parts).
- a feeder has the task of avoiding the formation of voids (cavities) in a casting, and has other different tasks in a casting mold:
- the exothermic feeders described in DE 10 2007 012 489 A1 contain thermally similar mixtures which are very dangerous and have led to extreme fires in some factories.
- the thermite reaction is a redox reaction in which aluminum is used as a reducing agent, e.g. Iron (III) oxide to reduce iron.
- the mixture is called thermite:
- the reaction products are alumina and elemental iron.
- the reaction is very exothermic, ie under strong heat.
- the ignition medium used is barium peroxide with magnesium.
- Thermitgemische are not explosives and can be brought to implementation (inflammation) only by a very large heat input (activation energy).
- the burning process is a strongly exothermic reaction (up to 3000 ° C). Since burning thermite does not require external oxygen, the reaction can not be stifled and in any environment - even under sand or water - be ignited and continue to burn. Extinguishing tests with water and moisture lead to a further redox reaction, in which the water is reduced by the less noble metals and thus metal oxide and hydrogen are formed:
- base material mixed with binder with a certain firing pressure and possibly defined working temperature is introduced into a core mold (the "core box"). After hardening or precuring of the casting core thus produced, it is installed in the casting mold.
- core box a core mold
- so-called cold box or hot box core shooting machines are used.
- the blends in the present patent application contain significantly more water. In the recipe, the water content is at least 10 wt% and larger. The blends in the present patent application therefore correspond to their consistency ramming masses or plastic masses.
- the binders listed in DE 10 2007 012 489 A1 are exclusive
- Thermoplastics also known as plastomers, are plastics that can be deformed in a specific temperature range (thermo-plastic). This process is reversible, that is, it can be repeated as often as desired by cooling and reheating to the molten state, as long as not using the so-called thermal decomposition of the material by overheating.
- Thermoplastics are mainly processed by injection molding, which is similar to the core shooting method described in DE 10 2007 012 489 AI.
- the thermoplastics include z. Acrylonitrile-butadiene-styrene (ABS), polyamides (PA), polylactate (PLA), polymethylmethacrylate (PMMA), polycarbonate (PC),
- PET Polyethylene terephthalate
- PE polyethylene
- PP polypropylene
- PS polystyrene
- PEEK polyetheretherketone
- PVC polyvinyl chloride
- thermoplastic binders In no way are the properties of thermoplastic binders to be compared with the hybrid binders described in the present patent application which must ensure strength over a wide temperature range.
- the invention has for its object to provide extremely stable moldings of the type mentioned, which have a density of less than 1.0 g / cm 3 , to about a maximum of 1500 ° C virtually no shrinkage, namely less than 1.0%, and show up to this temperature no external or internal cracks and no crumbling and for continuous temperatures up to about 1600 ° C are suitable and the one clearly show higher cold compressive strength than refractory bricks comparable gross density and comparable thermal conductivity show.
- the geometry of the molded parts is basically no limit. Bricks, pipes, hollow bodies and other molded parts can be produced.
- aqueous mass which are prepared by known shaping processes, subsequent drying and thermal treatment in various stages from 950 to about 1450 ° C.
- the following molding methods are suitable:
- the kaolin present in the plastic starting material is converted into spinel and quartz, which then serves as a binder for the not yet melted at this temperature volcanic rocks.
- the surface of the cenospheres can be adjusted to the requirements in a targeted manner by adding or exchanging minerals and melts in the flux. With approximately the same densities and thermal properties can be adjusted to the requirements in a targeted manner by adding or exchanging minerals and melts in the flux. With approximately the same densities and thermal properties can be adjusted to the requirements in a targeted manner by adding or exchanging minerals and melts in the flux. With approximately the same densities and thermal properties can be adjusted to the requirements in a targeted manner by adding or exchanging minerals and melts in the flux. With approximately the same densities and thermal properties can
- lightweight flameproof can be used up to 1600 ° C moldings with adapted to the intended use surfaces of the cenospheres.
- the content of fibers and / or wollastonite serves to cohesion of the mass in the wet state.
- the hybrid binder provides for the cohesion after drying at temperatures up to about 200 ° C due to the organic component and at higher temperatures by the sintering of the silica particles.
- the kaolin used and the silica sol are also a binder, which at elevated
- the light fillers namely the microcellularly expanded volcanic rocks and the cenospheres provide the necessary volume and a relatively low density compared to the prior art.
- the microcellularly inflated volcanic rocks soften at temperatures above about 1000 ° C and higher and then serve as a flux and binder between the
- microcellular expanded volcanic stones are surface treated to protect against water attack in the plastic masses and mortars, thereby rendering the masses shelf stable.
- inflated cellular volcanic rock in the form of nonporous hollow granules is used as light filler.
- porous hollow granules on the other hand, the bulk density would increase, more glue and more minerals would be required, the masses would become duller and thus would be worse to process and the porosity of the end product would increase significantly.
- the main constituent of the composition according to the invention are fly ash cenospheres, which in particular have a proportion of from 20 to 45% by weight.
- Fly ash is the solid, disperse (particulate, particulate, dusty) residue of burns, which is due to its high dispersity (fineness) discharged with the flue gases. Fly ash is produced in large quantities in
- the particle size ranges from about 1 ⁇ to 1 mm.
- Particle shapes include both smooth, massive spheres and hollow spheres (so-called cenospheres), platelets, fibers and agglomerates.
- the density is 2.2 to 2.4 kg / dm 3
- the bulk density is between 0.9 to 1.1 kg / dm 3 .
- the composition of the fly ash strongly depends on the fuel (lignite or
- Hard coal and extends from residual carbon and minerals (quartz) to toxic substances such as heavy metals (arsenic to zinc) and dioxins.
- the fly ash also acts as a carrier of adsorbed pollutants. While pure, uniform, consistent fuels such as hard coal provide a good usable fly ash, the brown coal fly ash (BFA) is composed of many different substances. Due to their chemical and physical properties, such as the pozzolanic reactivity, the spherical grain shape and the grain distribution, hard coal fly ash (SFA) in particular is a high - quality secondary raw material and is found in the
- fly ash is used in the building materials industry according to DIN EN 450 as an additive in cement and concrete. Furthermore, the fly ash can be used for the production of bricks made of sand-lime brick or aerated concrete. In road and earthworks, the fly ash is used together with Gesteinskömung as a building material for unbound base courses.
- Kaolin / Silica Kieselsol Kaolin also referred to as china clay or aluminum silicate, is a fine, iron-free, white rock containing as its main constituent kaolinite, a weathering product of feldspar.
- the kaolin used as a film covers the high-melting light filler and forms a solid structure even at about 900 ° C.
- Shrinkage is affected by the ratio of kaolin / silica / silica sol and their distribution.
- Another advantage of the used mixture of kaolin silica silica sol is that the mass after hardening is hard and mechanically stable.
- Binders is used with a binding effect in different temperature ranges.
- the innovation of the product according to the invention is, in particular, that suitable, complementary binder systems are used, for. B. the
- Hybrid binder which already has the support structures made of fibers in the
- Volcanic rocks as a flux for the additional minerals and as a fixation for the cenospheres. Due to the cavities formed by the melting, stresses can be buffered by increasing the temperature and expanding within the mass.
- a key customer benefit when using the products according to the invention is that in addition to the desired goal of efficient high-temperature insulation a Significant cost savings in the area of opportunity costs for customers can be realized. The reduction of these costs is achieved primarily by improving the energy balance and also the life cycle assessment by reducing emissions for the customer.
- Perlite (English: perlite) referred to in geosciences an altered (chemically and physically transformed) volcanic glass (obsidian) and is thus one of the rocks.
- the so-called pearlitic structure is formed here by approximately pea-sized glass beads.
- Perlite contains up to 2% water and has a density of about 900 to 1000 kg / m 3 (bulk density of crude perlite).
- microcellularly-expanded volcanic rocks are suitable for the purposes of the invention, produced according to new environmentally friendly and energy-saving methods, and achieve properties and technical values that expand from older, porous ones
- Microcellular, expanded volcanic rock is a filler from the group of aluminum silicates and consists of spherical ("honeycomb"), rod-shaped and flaky particles resulting in high packing densities and higher bond strengths than conventional hollow microspheres due to mechanical and cohesive bonding forces.
- Targeted surface coatings enable an advantageous bond with the inorganic or organic matrix. This results in less shrinkage and better technical properties.
- Commercially available is blown impregnated perlite z. B. under the trade name NOBLITE® (product of the company NOBLITE, Route de Claye, F-77181 LE PIN, France) and Technoperl® (product of Europerl Germany, D-94032 Passau, Nibelebenplatz 4).
- ceramic and / or mineral high-melting fibers and / or organic high-melting fibers, for example carbon fibers are used.
- Wollastonite is also possible.
- Ceramic fibers or ceramic fibers are fibers
- inorganic, non-metallic material inorganic, non-metallic material.
- ceramic polycrystalline inorganic materials
- precursors produced by pyrolysis amorphous fibers, which are referred to by their properties as ceramic fibers.
- amorphous glass fibers which are not counted among the ceramic fibers, is best made possible by the manufacturing process (glass fibers from glass melt, amorphous ceramic fibers from polymeric precursors by pyrolysis).
- the ceramic fibers are classified into oxidic and non-oxidic.
- oxidic ceramic fibers fibers based on alumina and silica in different proportions and in part even with additional boron oxide or zirconium oxide are known.
- Mixed oxide fibers of 85% A1 2 0 3 and 15% Si0 2 are also referred to as mullite fibers. All of these fibers are polycrystalline.
- Non-oxide, industrially produced fibers have various types of silicon carbide fibers known.
- Starting polymers are almost exclusively so-called poly-carbosilanes. These are polymers of hydrocarbons in which individual carbon atoms have been replaced by silicon atoms or silanes in which individual silicon atoms have been replaced by carbon atoms. Additives crosslink the polymers in a hardening process so that they can be used after the P2011 / 000872
- Spinning process in the pyrolysis not simply evaporate, but - as in the production of carbon fibers - are converted into an amorphous, usually non-stoichiometric, still free carbon-containing SiC ceramic fiber.
- an organic-inorganic hybrid binder which is obtainable under the trade name COL.9 from BASF. It contains 50 to 100 nm composite particles containing amorphous silica particles 5 and a polymer 6 based on n-butyl acrylate and methyl methacrylate (see Figure 1). The particles are dispersed in water. Due to the stickiness of the particles due to the polymer content is obtained an excellent binder for low temperatures, up to about 200 ° C. At elevated temperatures, the polymer fraction decomposes and the silica particles remain and thus preserve the structure, wherein the silica particles also forms a solid framework at a correspondingly high temperature. Shrinkage therefore does not occur at low or elevated
- the binder has a solids content of about 35 to 40% by weight.
- the silicate content, based on the solids content, is 30 to 50 wt .-%.
- a surface-treated silica is used.
- Silica is an intimate mixture of finely divided silica and kaolinite.
- the Neuburg Siliceous Earth is known, which is preferably used according to the invention.
- the silica is treated with a silane so that the individual particles have a functional hydrophilic surface.
- Such an activated silica is available under the trade name "AKTISIL EM” from Hoffmann Mineral GmbH, Neuburg (Danube) Here, the silica is treated with 3-epoxypropyloxipropyltrimethoxysilane.
- This so-called activated silica can be used in powder form the use of a mixture of silica sol and kaolin / kaolinite. Production examples and example formulations for the plastic mass used to produce the molded parts
- step 1 mix all the liquid components of the recipe; then the components are weighed separately according to the recipe. step 1
- Mixer to be used e.g. beba compulsory mixer
- the premix now has a creamy consistency and may no longer contain lumps. If there are any lumps left, rasp them by hand, mix again with the same setting until there are no more lumps.
- the mass must correspond to a loose bed to a pourable mortar.
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- Ceramic Engineering (AREA)
- Organic Chemistry (AREA)
- Materials Engineering (AREA)
- Structural Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Inorganic Chemistry (AREA)
- Dispersion Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Combustion & Propulsion (AREA)
- Environmental & Geological Engineering (AREA)
- Compositions Of Macromolecular Compounds (AREA)
- Curing Cements, Concrete, And Artificial Stone (AREA)
- Porous Artificial Stone Or Porous Ceramic Products (AREA)
- Compositions Of Oxide Ceramics (AREA)
Abstract
Description
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Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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DE201010009148 DE102010009148B4 (en) | 2010-02-24 | 2010-02-24 | Heat-insulating refractory high temperature resistant molding |
PCT/EP2011/000872 WO2011104008A2 (en) | 2010-02-24 | 2011-02-23 | Heat-insulating refractory high-temperature resistant molded article |
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EP2539295A2 true EP2539295A2 (en) | 2013-01-02 |
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EP11709864A Ceased EP2539295A2 (en) | 2010-02-24 | 2011-02-23 | Heat-insulating refractory high-temperature resistant molded article |
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EP (1) | EP2539295A2 (en) |
DE (1) | DE102010009148B4 (en) |
WO (1) | WO2011104008A2 (en) |
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DE102010048174B4 (en) | 2010-10-13 | 2015-04-02 | TDH - GmbH Technischer Dämmstoffhandel | Intumescent heat-insulating refractory molding and process for its production |
DE102010048175B4 (en) | 2010-10-13 | 2016-07-21 | Werner Bloem | Active pollutant-reducing molding |
CN109562997A (en) | 2016-08-19 | 2019-04-02 | 瓦克化学股份公司 | The porous molding of insulating plasters layer or insulating panel form |
CN106495738B (en) * | 2016-10-25 | 2019-04-16 | 中电声韵声学工程技术(北京)有限公司 | A kind of ceramic sound-absorbing material and preparation method thereof and purposes |
CN111732424A (en) * | 2020-07-14 | 2020-10-02 | 黑龙江火山岩科技有限公司 | Volcanic low-expansion ceramic blank and preparation method of volcanic low-expansion ceramic |
CN111995419A (en) * | 2020-09-02 | 2020-11-27 | 巩义市益鑫耐火材料厂 | Environment-friendly reinforced composite dephosphorization coated brick for molten iron pretreatment and preparation method thereof |
CN113511904B (en) * | 2021-04-22 | 2022-06-14 | 武汉科技大学 | Light-weight mullite refractory material and preparation method thereof |
CN113563092B (en) * | 2021-07-29 | 2023-12-22 | 阿尔赛(苏州)无机材料有限公司 | Hollow sphere ceramic fiber brick and preparation method thereof |
CN116553921B (en) * | 2023-02-27 | 2024-06-25 | 河南三元光电科技有限公司 | High-temperature-resistant heat-insulating composite material and preparation method thereof |
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US3847633A (en) * | 1972-04-10 | 1974-11-12 | Litvin R | Building material for modular construction |
GB1499804A (en) * | 1974-12-17 | 1978-02-01 | Hartfree A | Thermally insulating and fire resistant compositions and articles made therefrom |
CN1158323A (en) * | 1996-11-21 | 1997-09-03 | 张运勇 | Light wall thermal insulating and fire-proof paste |
EP1829838B1 (en) * | 2000-03-14 | 2016-08-24 | James Hardie Technology Limited | Fiber cement building materials with low density additives |
CN100422118C (en) * | 2000-10-17 | 2008-10-01 | 小田建设株式会社 | Porous, sound absorbing ceramic moldings and method for production thereof |
KR20050031196A (en) * | 2003-09-29 | 2005-04-06 | 최준한 | Incombustible composition, incombustible material for architecture using the same and preparing method thereof |
DE102007012489A1 (en) * | 2007-03-15 | 2008-09-25 | AS Lüngen GmbH | Composition for the production of feeders |
CN101172870A (en) * | 2007-10-18 | 2008-05-07 | 李哲 | Fireproof thermal insulation material |
-
2010
- 2010-02-24 DE DE201010009148 patent/DE102010009148B4/en active Active
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2011
- 2011-02-23 EP EP11709864A patent/EP2539295A2/en not_active Ceased
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WO2011104008A2 (en) | 2011-09-01 |
DE102010009148A1 (en) | 2011-08-25 |
WO2011104008A3 (en) | 2011-10-20 |
DE102010009148B4 (en) | 2013-10-10 |
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