GB2044750A - Production of Refractory Bricks - Google Patents

Production of Refractory Bricks Download PDF

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Publication number
GB2044750A
GB2044750A GB8008415A GB8008415A GB2044750A GB 2044750 A GB2044750 A GB 2044750A GB 8008415 A GB8008415 A GB 8008415A GB 8008415 A GB8008415 A GB 8008415A GB 2044750 A GB2044750 A GB 2044750A
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Prior art keywords
bricks
pitch
pressure
temperature
process according
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GB8008415A
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GB2044750B (en
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Magnesital Feuerfest GmbH
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Magnesital Feuerfest GmbH
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Classifications

    • 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
    • C04B35/013Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics containing carbon
    • 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
    • C04B41/00After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/009After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone characterised by the material treated
    • 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
    • C04B41/00After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/45Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
    • C04B41/50Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials
    • C04B41/5001Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials with carbon or carbonisable materials
    • 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
    • C04B41/00After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/80After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only ceramics
    • C04B41/81Coating or impregnation
    • C04B41/85Coating or impregnation with inorganic materials

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Inorganic Chemistry (AREA)
  • Ceramic Products (AREA)
  • Furnace Housings, Linings, Walls, And Ceilings (AREA)
  • Manufacture And Refinement Of Metals (AREA)

Abstract

Bricks based on sintered magnesite and/or dolomite mixed with tar or pitch are formed and tempered; the resultant bricks are then heated such that their core temperature is in the range of from 190 DEG to 230 DEG C and their surface temperature is no more than 20 DEG C above the core temperature. The heated bricks are exposed to a pressure of less than 30 Torr for at least 4 minutes, and whilst exposed to this low pressure the bricks are impregnated with tar or pitch which is preferably heated to between 100 DEG C and 140 DEG C above its softening temperature. Exposure of the bricks to a pressure of between 3 and 6 atmosphere gauge pressure produces refractory unfired bricks having a residual carbon content of at least 5.5% by weight. The bricks can be used for lining vessels such as converters and electric melting furnaces.

Description

SPECIFICATION Process for the Production of Refractory Bricks The present invention relates to a process for the production of refractory bricks based on magnesite and/or dolomite and suitable for use in lining melting vessels, particularly but not exc,lusively converters and electric melting furnaces.
It is known to make refractory unfired bricks by mixing sintered raw material of magnesite or dolomite with tar or pitch, forming the bricks from the resultant mixture and tempering the bricks thus formed. During the tempering, a major proportion of the volatile constituents contained in the tar or pitch are driven off. A carbon skeleton is thus formed in the brick, the level of the carbon content (residual carbon content) of which substantially determines the resistance to slag penetration and the durability of the bricks when used in the melting vessels.
Since the addition of tar or pitch to the sintered raw material is subject to an upper limit due to problems which may otherwise be encountered on forming the bricks, many proposals have been put forward to increase the residual carbon content by other means. Thus, in addition to tar or pitch, solid carbon has been added to the sintered raw material for example in the form of lampblack or graphite. However, the solid carbon carrier in finely distributed form can have an undesirable influence on the moulding properties of the bricks. In this way, both the gross density and the apparent porosity, which are a measure of resistance to slag infiltration, in addition to the cold compression strength can be impaired as compared with those of tar-bound tempered bricks.
Thus, a tar-bound tempered brick having a residual carbon content of 4.5% can have a gross density of about 3.04 g/cm3, an apparent porosity of about 7.0% and a cold compression strength of more than 35 N/mm2. If the residual carbon content of such a brick is raised to 5.5% by the addition of solid carbon, the gross density falls to 3.0 g/cm3, the apparent porosity rises to 10% and the cold compression strength falls to about 30 N/mm2.
A method of raising the carbon content of tarbound bricks involving spraying or spreading on liquid tar or dipping the bricks in liquid tar has also been described. By this coating method, which should be applied before the tempering treatment, the carbon content can only be raised to a minor extent in the outer brick layers (DE-OS 1 5 71 411, more particularly page 6, paragraph 2, and claim 12).
It is further known to temper tar-bound or pitch-bound dolomite or magnesite bricks at 3000C and under a pressure of 20 atmosphere gauge and to impregnate the bricks a plurality of times with tar or oils. The bricks are thereafter heated to 5000C to 6000C at a pressure of 20 atmospheres gauge. By means of this thermal after-treatment under superatmospheric pressure substantially all the volatile hydrocarbons are caused to escape from the brick. The elasticity of the brick is thereby lowered and it becomes vulnerable to sudden changes in temperature during its use in a melting furnace (DE-PS 12 06 778, column 5, Example 2).
The present invention has for its object to provide a process for making magnesite or dolomite based refractory bricks in which the residual carbon content of the bricks can be enhanced and the bricks themselves are given improved resistance to slag infiltration and hence greater durability when used in a furnace, According to the present invention there is provided a process for making refractory bricks comprising the steps of:: (i) heating tempered bricks formed from a mixture containing sintered magnesite and/or dolomite and tar or pitch, the heating being such that the core temperature of the bricks is in the range of from 1 900C to 2300C and the surface temperature of the bricks is not more than 200C above the said core temperature; (ii) exposing the heated bricks of step (i) to low pressure of less than 30 Torr for at least 4 minutes; (iii) impregnating the bricks whilst exposed to the pressure of step (ii) with tar or pitch heated to above its softening temperature; and (iv) exposing the bricks of step (iii) to a pressure of between 3 and 6 atmosphere gauge pressure, thereby producing refractory bricks having a carbon content of at least 5.5% by weight.
Step (i) preferably comprises heating the bricks so that their core temperature is within the range of from 1950Cto 21 OOC and their surface temperature is not more than 100C above the said core temperature. In step (ii) the bricks are preferably exposed to a pressure within the range of from 15to 10 Torr for between 6 to 8 minutes and in step (iv) to a pressure of between 4.5 and 5.5 atmosphere gauge pressure. The pitch employed in step (iii) is preferably heated to a temperature which is in the range of from 1000C to 1 400C, more preferably 11000 to 1300C, above its softening temperature.
In one form of the invention pitch used in step (iii) for impregnating the bricks has one or more of the following characteristics: (a) a high molecular weight; (b) a softening temperature greater than 700C; (c) a quinoline-insoluble fraction of less than 3%; and (d) a degree of carbonisation of more than 40%.
By a pitch of "high molecular weight" is meant a pitch which preponderantly contains constituents having a high molecular weight especially constituents having a molecular weight of more than 1 70. Quinoline is a known testing reagent for ascertaining the resinous content in pitch. In the claims and throughout the specification "the degree of carbonisation of the pitch" is that according to Conradson and defined in German Industrial Standard No. DIN 51551. Preferred embodiments of the pitch used for impregnating the bricks include a softening temperature of more than 800 C, a quinoline-insoluble fraction of less than 1.5% and a degree of carbonisation of more than 45%.
Bricks produced by the present process have a residual carbon content of at least 5.5% by weight and can have a gross density of more than 3.12 g/cm3, an apparent porosity of about 1.0% and a cold compression strength of more than 50 N/mm2.
As compared with bricks based on the same raw materials, but only pitch-bound or tar-bound and tempered, the bricks produced by the present process can be up to 25% more durable. The increase in durability appears to be due to one or more of the following factors.
1. Due to the high residual carbon content, the bricks have a higher resistance to slag infiltration.
2. Owing to the presence of liquid phases during the heating up of the bricks in use, the bricks are more elastic.
3. During the tar or pitch impregnation, the bricks acquire a thin surface layer of adhering tar or pitch which can allow expansion during the heating up of the bricks in use. Since refractory materials undergo thermal expansion with an increase of temperature, the expansion can result in high stresses in extreme cases so that spalling occurs. Bricks produced in accordance with the present process need not require any additional expansion gaps and can be laid without expansion joints.
4. Due to the fact that volatile constituents of the impregnated pitch remain in the brick and in use creep towards the brick's hot surface as the temperature progressively increases towards the cold end of the brick, a vapour cushion is formed at the boundary layer between the brick material and the liquid medium (steel and slag) which prevents or reduces the penetration of liquid media.
Embodiments of the present invention will now be described with reference to the following Examples: Example I About 94% by weight of sintered magnesite (MgO content about 96% by weight) was mixed with about 3.0% by weight of tar (softening point above 750C, distillation residue at 3600C above 90% by weight, carbon content according to Conradson of more than 40% by weight) and about 3.0% of carbon-containing additives.
The mass was moulded to form bricks under a pressure of 1200 kg/cm2 at a temperature of about 1 350C. Thereafter, the bricks were tempered at about 3200C for 1 5 hours, a major proportion of the volatile constituents contained in the tar being driven off.
The residual carbon content of the tempered bricks amounted to about 4.5% by weight; the gross density to about 3.04 g/cm3; the apparent porosity to about 7% and the cold compression strength to about 35 N/mm2.
After tempering, the bricks were heated in preparation for the tar impregnation such that the core temperature in each brick was 2000C and the surface temperature of each brick was not more than 10"C above the core temperature. The bricks were next held at a low pressure of 10 Torr for 6 minutes and the pitch impregnation then carried out. The pressure in the pressure chamber was then raised to 5 atmospheres gauge pressure for a short while. The pitch used for the impregnations had a high molecular weight, a softening point of about 850C and a degree of carbonisation according to Conradson of about 50% and contained about 1.5% by weight of quinoline-insoluble fractions.
The residual carbon of the bricks produced, which once cooled were ready for despatch, amounted to 5.5% by weight, the gross density to 3.12 g/cm3 and the apparent porosity to about 1.0%, the difference between the apparent porosity at the edge and at the core being less than 0.5% and the cold compression strength being > 50 N/mm2.
When the bricks were used in an oxygen surface blast converter, the bricks endured 480 charges, with an average charge weight of 255 t of steel. In comparison, bricks based on the same raw materials, but not subsequently impregnated had a durability of only 410 charges. The bricks of the present example thus show an increase of durability of about 15% (with respect to the improved performance).
When the bricks were used in a bottom blown converter, a durability of about 320 charges was obtained with a tap weight of about 60 t of steel.
In comparison, bricks based on the same raw materials, but not subsequently impregnated had a durability of only 270 charges. An increase of durability of about 15% is thus shown by bricks of the present example (with respect to the improved performance).
When the bricks were used in a slag zone of an electric melting furnace, a durability of 100 charges was obtained with a charge weight of 100 t of steel at a time. In comparison, bricks based on the same raw materials, but not subsequently impregnated have a durability of only 80 charges. An increase of durability of about 20% is thus achieved (with respect to the improved performance).
Example II About 35% of sintered magnesite (MgO content about 96% by weight) and about 65% of low-iron dolomitic magnesite (MgO content about 87% by weight) were mixed with about 3.0% by weight of tar (softening point above 750C, distillation residue at 3600C above 90% by weight, carbon content according to Conradson of more than 40% by weight) and about 3.0% of carbon carriers.
The mass was moulded to form bricks under a pressure of 1200 kg/cm2 at a temperature of about 1 350C. thereafter, the bricks were tempered at about 3200C for 1 5 hours, the major proportion of the volatile constituents contained in the tar being driven off. The residual carbon content of the tempered bricks was about 4.5% by weight, the gross density about 2.98 g/cm3, the,apparent porosity about 9% and the cold compression strength about 30 N/mm2.
The bricks were then vacuum-impregnated with pitch under the same conditions as indicated in Example I.
The residual carbon content of the bricks produced which once cooled were ready for despatch was about 5.6% by weight, the gross density was about 3.08 g/m3, the apparent porosity was about 1.8% the difference in the apparent porosity between the edge and the core was less than 0.5%, and the cold compression strength was about 55 N/mm2.
When the tempered bricks of the present Example were used in an oxygen surface blast converter with average tap weights of about 200 t, the average durability was generally about 450 charges, but when the tempered and pitchimpregnated bricks were used the average durability was about 520 charges. An increase in durability of about 13% is thus shown (with respect to the improved performance).

Claims (10)

Claims
1. Process for making refractory bricks comprising the steps of: (i) heating tempered bricks formed from a mixture containing sintered magnesite and/or dolomite and tar or pitch, the heating being such that the core temperature of the bricks is in the range of from 1 900C to 2300C and the surface temperature of the bricks is not more than 200C above the said core temperature; (ii) exposing the heated bricks of step (i) to low pressure of less than 30 Torr for at least 4 minutes; (iii) impregnating the bricks whilst exposed to the pressure of step (ii) with tar or pitch heated to above its softening temperature; and (iv) exposing the bricks of step (iii) to a pressure of between 3 and 6 atmosphere gauge pressure, thereby producing refractory bricks having a carbon content of at least 5.5% by weight.
2. Process according to claim 1 wherein step (i) comprises heating the bricks so that their core temperature is within the range of from 1 950C to 21 00C and their surface temperature is not more than 1 0CC above the said core temperature.
3. Process according to claim 1 or claim 2 wherein step (ii) comprises exposing the bricks to a pressure within the range of from 1 5 to 10 Torr for between 6 and 8 minutes.
4. Process according to any one of the preceding claims wherein step (iv) comprises exposing the bricks to a pressure of between 4.5 and 5.5 atmosphere gauge pressure.
5. Process according to any one of the preceding claims wherein step (iii) comprises impregnating the bricks with pitch heated to a temperature which is in the range of from 1000C to 1 400C above its softening temperature.
6. Process according to claim 5 wherein the said range is from 11 00C to 1 300C above the softening temperature of the pitch.
7. Process according to any one of the preceding claims wherein step (iii) comprises impregnating the bricks with pitch which has one or more of the following characteristics: (a) a high molecular weight; (b) a softening temperature greater than 700C; (c) a quinoline-insoluble fraction of less than 3%; and (d) a degree of carbonisation of more than 40%.
8. Process according to claim 7 wherein the pitch has one or more of the following characteristics: (b) a softening temperature greater than 800C; (c) a quinoline-insoluble fraction of less than
1.5%; and (d) a degree of carbonisation of more than 45%.
9. Process for making refractory bricks substantially as herein described with reference to Example I or Example II.
10. Refractory unfired bricks made by a process according to any one of the preceding claims.
GB8008415A 1979-03-16 1980-03-12 Production of refractory bricks Expired GB2044750B (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
DE2910309A DE2910309C2 (en) 1979-03-16 1979-03-16 Process for the production of refractory, unfired bricks

Publications (2)

Publication Number Publication Date
GB2044750A true GB2044750A (en) 1980-10-22
GB2044750B GB2044750B (en) 1982-10-20

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GB8008415A Expired GB2044750B (en) 1979-03-16 1980-03-12 Production of refractory bricks

Country Status (7)

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AT (1) ATA141580A (en)
DE (1) DE2910309C2 (en)
FR (1) FR2451348B1 (en)
GB (1) GB2044750B (en)
GR (1) GR68400B (en)
IT (1) IT1130056B (en)
NL (1) NL8001436A (en)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1993017979A1 (en) * 1992-03-08 1993-09-16 Veitsch-Radex Aktiengesellschaft Für Feuerfeste Erzeugnisse Process for producing a fireproof compound and a fireproof moulding
EP1138646A1 (en) * 1999-09-24 2001-10-04 Shinagawa Refractories Co., Ltd. Carbonaceous refractory with high resistance to spalling and process for producing the same

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3620473A1 (en) * 1986-06-19 1987-12-23 Dolomitwerke Gmbh FIRE RESISTANT MEASUREMENT FOR FIRE RESISTANT LININGS OF METALLURGICAL VESSELS
DE3941978A1 (en) * 1989-12-20 1991-06-27 Feist Horst Julius METHOD FOR TEMPERING CARBONED BLANKS

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR1372051A (en) * 1963-08-06 1964-09-11 Harbison Walker Refractories Process for impregnating porous ceramic shapes, calcined
US3436237A (en) * 1966-10-25 1969-04-01 Green Refractories Coke bonded basic refractory
US3903025A (en) * 1973-11-06 1975-09-02 Gen Refractories Co Method for cold molding pitch bonded refractory

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1993017979A1 (en) * 1992-03-08 1993-09-16 Veitsch-Radex Aktiengesellschaft Für Feuerfeste Erzeugnisse Process for producing a fireproof compound and a fireproof moulding
EP1138646A1 (en) * 1999-09-24 2001-10-04 Shinagawa Refractories Co., Ltd. Carbonaceous refractory with high resistance to spalling and process for producing the same
EP1138646A4 (en) * 1999-09-24 2005-03-30 Shinagawa Refractories Co Carbonaceous refractory with high resistance to spalling and process for producing the same

Also Published As

Publication number Publication date
DE2910309C2 (en) 1982-08-19
GR68400B (en) 1981-12-29
ATA141580A (en) 1984-09-15
NL8001436A (en) 1980-09-18
FR2451348A1 (en) 1980-10-10
DE2910309A1 (en) 1980-09-18
IT8020640A0 (en) 1980-03-14
FR2451348B1 (en) 1986-10-10
GB2044750B (en) 1982-10-20
IT1130056B (en) 1986-06-11

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