GB2052472A - Process for the production of heat-insulating bonded fibrous articles - Google Patents

Process for the production of heat-insulating bonded fibrous articles Download PDF

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Publication number
GB2052472A
GB2052472A GB8018808A GB8018808A GB2052472A GB 2052472 A GB2052472 A GB 2052472A GB 8018808 A GB8018808 A GB 8018808A GB 8018808 A GB8018808 A GB 8018808A GB 2052472 A GB2052472 A GB 2052472A
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Prior art keywords
fibrous
heat
fibrous material
article
phosphate solution
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GB8018808A
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GB2052472B (en
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Didier Werke AG
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Didier Werke AG
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    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/34Compositions 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 cold phosphate binders

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Compositions Of Oxide Ceramics (AREA)
  • Inorganic Fibers (AREA)
  • Paper (AREA)

Abstract

A process for the production of a heat-insulating bonded fibrous article from fibrous material, especially ceramic fibrous material, includes forming a slurry of the material and then forming it to the desired shape (e.g. a mat). Before or after the material is shaped or bonded it is soaked with a monoaluminium phosphate solution and the material is then dried and heat treated at at least 400 DEG C and thereafter optionally fired.

Description

SPECIFICATION Process for the production of heat-insulating bonded fibrous articles The invention relates to the production of heat-insulating bonded a Licles incorporating fibres, in particular ceramic fibres.
Heat-insulating ceramic fibrous articles made from refractory fibres and organic or inorganic bonding agents are known having either low rigidity and high compressibility or high values for rigidity, density and stability of shape. German Auslegeschrift No. 1274490 describes a combustion chamber for furnaces which is formed by shaping such fibrous material with an added bonding agent and in which the concentration of the bonding agent decreases over the cross-section of the wail. Clays, alkali silicates, colloidal silica in a proportion of 5% to 35%, and preferably 1090, by weight are given as suitable bonding agents. However, because of its dense hard wall surface and the softness of the opposed flexible wall surface such a combustion chamber is not suitable for high stresses.
In the process disclosed in German Aus!sgeschrift No. 2732387 a mineral fibre plate is prebound with an organic plastics bonding agent and hardened by soaking with an aqueous slurry of a bonding clay followed by heat treatment. The process disclosed in German Offenlegungsschrift No. 1 646696 provides for the stiffening of a heat insulation made from a layer of fibres by treating the surface and part of the underlying layer with a silicate sol. The heat insulation treated in this way may also be used as a lining for a spout for molten metal.In German Ausiegeschrift No. 2049054 shaped members made from refractory heat-insulating material of homogeneous structure are obtained using microwave drying and used, for example, for insulating turbine housings or for lining gas convectors and furnaces.
Mixtures or a colloidal silica sol and aluminium silicate fibres are stated to be the preferred composition.
However, this heat-insulating fibrous material has the disadvantage that it is not sufficiently stable, corrosion-resistant and deformation resistant at high temperatures.
An object of the invention is to avoid the disadvantages which previously occurred in heat insulating reinforced fibrous articles, especially those made from ceramic fibres, and to provide Fibrous articles which have a high resistance to expansion and contraction and to erosion as well as a high chemical resistance to hot corrosive gases, especially acidic gases, whilst leaving the gross density and heat conductivity substantially unchanged. Such corrosive gases may contain, for example, sulphurdioxide, chlorine or fluorine as acid-reacting constituents which severely attack or corrode the fibres, especially ceramic fibres, used for the production of the fibrous articles.
According to the present invention there is provided a process for the production of a heatinsulating bonded fibrous article from fibrous material in which the fibrous material is shaped and then wetted with an aqueous monoaluminium phosphate solution and heat treated at a temperature of at least 4000 C. The monoaluminium phosphate may act as the sole bonding agent, or additional bonding agents may also be present. After the heat treatment the article is preferably fired at a higher temperature, which temperature is preferably between 800 and 1 4000C.
Preferably the fibrous material comprises ceramic fibres and prior to the heat treatment the fibrous material is conveniently dried, The monoaluminium phosphate solution convenientiy has a concentration of 20 to 50% by weight, and preferably 30 to 40%. It has been found that optimum bonding and also resistance to expansion and contraction of the fibrous article at high temperatures are achieved using such a concentration. With a higher concentration there is a danger of perceptible structural alteration when the fibrous article is used.Thus fibrous articles made from aluminium silicate fibres with 47% by weight Awl203 did not show any shrinkage after treatment for one hour with a 40% monoaluminium phosphate solution and firing at 1 OOQOC for 4 hours, whereas with a 50% monoaluminium phosphate solution a linear expansion of approximately i /0 was observed.
As mentioned above, the fibrous articles are preferably fired at 800 to 1 4000 C, which may produce an improvement in the resistance to expansion and contraction of the material. However, it is not necessary in every case to fire the heat treated fibrous articles since this firing or heating to higher temperatures can take place when the fibrous articles are first used, for example as a lining in a furnace or a reaction vessel.
It has also proved advantageous to add a small quantity of sodium polyphosphate during the production of the fibrous articles. This may either be added to the monoaiuminium phosphate solution in solid or dissolved form, preferably in an amount comprising 0 to 1 5% by weight of the monoaluminium phosphate present, or it may be added directly to the ceramic fibre slurry prior to or during formation of the fibrous articles, whereafter the monoaluminium phosphate solution is added. In the latter case the sodium polyphosphate is preferably added in finely divided solid form in an amount of between 0 and 5% by weight of the ceramic fibres.
In the production or shaping of the fibrous articles the known methods can be used, such as vibrating and pressing a moist crumbly mixture of ceramic fibres and bonding agent or pouring a suspension into a mould provided with perforated bottom and draining off the liquid. Reference may be made to German Auslegeschrift No. 1 94601 8 for the procedure in the latter process.
In a further embodiment of the invention, in which a further bonding agent is present, the fibrous material which has not yet hardened is completely soaked with the aqueous monoaluminium phosphate solution prior to the bonding and then the excess solution is removed. By this means the fibrous articles are formed in an advantageous manner and in addition a relatively small quantity of concentrated monoaluminium phosphate is used. It is also possible to proceed in such a way that the fibrous articles are bonded and dried and then completely soaked with the aqueous monoaluminium phosphate solution and the excess solution removed. The monoaluminium phosphate solution is generally added by applying to one side of the dry or wet article and then withdrawing the excess solution from the other side of the article, e.g. by the application of a vacuum.
The fibrous materials, especially ceramic materials, used for production of the fibrous articles are materials known per se, and are preferably based on aluminium silicates, particularly with a high Al203 content in the range of 45 to 95% by weight.
Mineral fibres such as mineral wool or glass fibres can also be used in the process according to the invention. These fibres are preferably used in chopped form, i.e. with a length of 1 to 5 mm, but it is also possible to use so-called ground fibres which have a length of 100 to 500 ym. The diameter of the fibre material is generally of the order of 1 to 25 zem, especially within the range from 2 to 8 ym. Naturally, it is also possible to use fibre material with other dimensions.
In the production of known fibrous articles it is already known to use bonding agents which may be of an inorganic or organic nature. Examples of inorganic bonding agents are clays, fine-ground fireclay, bauxite, alumina or bentonite, an example of an organic bonding agent being starch. In the process according to the invention, however, it is not absolutely essential to use such a bonding agent in addition to the monoaluminium phosphate which itself acts as a bonding agent, i.e. it is possible without adding anything else to produce a fibrous article from the fibrous material soaked in water in the conventional manner, for example with the aid of a suction box and to treat this fibrous material (before or after it is dried) according to the invention with the monoaluminium phosphate solution.
The term monoaluminium phosphate is used to mean the compound Al(H2PO4)3 which is commercially available as a 50% aqueous solution. Such a 50% aqueous solution can be further diluted with water as required.
Despite the fact that the fibrous materials used for the production of the fibrous articles may be partially attacked and corroded by phosphates including monoaluminium phosphate, the use of such fibrous materials together with monoaluminium phosphate is found to be surprisingly advantageous.
Thus it has been found that using the process according to the invention fibrous articles are obtained which are not only of high strength but also retain the structure and the maximum temperature of use of the fibrous materials.
The invention also relates to fibrous articles produced according to the invention which can be in conventional shapes such as mats, sheets, plates, tubes or the like.
The fibrous articles produced by the process according to the invention are particularly suitable, because of their resistance to erosion and their chemical stability, for lining pipes through which gases flow at great speed at high pressure and a high temperature. The fibrous articles can also be used as a heat-insulating material of low thermal capacity in furnaces, especially those containing an acidic atmosphere, as a layer lining the combustion chamber. The rigidity of the fibrous articles can be further improved and regulated by the addition of sodium polyphosphate.
The heat treatment carried out in the process according to the invention at a temperature of at least 4000C is carried out, in dependence upon the size and the shape of the fibrous article produced, for a period of in general 0.5 to 4 hours, preferably 1 to 3 hours, the maximum temperature for the treatment being usually 6000 C, and preferably 5500C.
The optional firing of the heat treated fibrous articles is also carried out depending upon the size and shape of the fibrous material, and is preferably over a period of 0.5 to 4 hours.
Naturally, it is also possible for the heat treatment to run into the firing treatment without an intervening gap and, especially in the case of fibrous articles of small dimensions where an internal thermal equilibrium is quickly reached, to heat the material only once to the firing temperature, especially 800 to 1400by, after drying the material, so that the heat and firing treatments are combined in one single treatment.
When the fibrous articles produced by conventional means are soaked with the monoaluminium phosphate solution, the solution is adsorbed by the fibrous material so that a certain quantity of monoaluminium phosphate remains on the fibres. This forms a protective coating for the fibres. The precise quantity of monoaluminium phosphate remaining on the fibres depends upon the concentration of the monoaluminium phosphate solution used and upon the diameter and the length of the fibres.
Simple preliminary tests have shown that by altering the concentration of the monoaluminium phosphate solution used for soaking and the force of the suction applied to the fibrous material it is possible to regulate the quantity of monoaluminium phosphate remaining in the fibrous articles. This can be easily determined chemically after completion of the fibrous articles and is usually given as the P2Q5 content. The fibrous articles produced according to the invention generally have a content of 5 to 38% by weight P20s, and preferably 10 to 32%.
Further features and details of the invention will be apparent from the following specific examples in which the article made is in each case a mat.
EXAMPLE 1 30 kg of ceramic silicate fibres containing 52% by weight Al203 and 48% by weight SiO2 as principal constituents in addition to the usual impurities having a length of 2 to 3 mm and a diameter of 2 to 3 u were mixed with 1.5 kg starch and 2.2 kg bentonite into 1800 litres water at ambient temperature. From this suspension a mat 25 mm thick was formed in a suction box of 500 x 1000 mm.
After extraction of the water the mat was dried for an hour at 1 200C. After drying a piece was cut from this mat for use as a reference sample.
The rest of the dried mat was completely soaked with 7 litres of a 33% by weight monoaluminium phosphate solution for ten minutes at ambient temperature, and then the excess monoaluminium phosphate solution was extracted from the mat using a sieve as a support. The mat was dried again at a temperature of approximately 1 300C and then the two mats were subjected to a reheating treatment at 4200C for two hours.
The mat which had been treated according to the invention with monoaluminium phosphate solution and reheated showed a content of 27% by weight P205 when analysed.
The following table shows the properties found in this mat by comparison with the properties of the reference sample mat which had not been treated with monoaluminium phosphate solution.
TABLE Mat not treated Mat according to with monoaluminium the invention phosphate solution gross density (g/cm3) 0.48 0.26 cold bending strength (N/mm2) 1.0 0.3 bending strength after 4 hours 1.0 0.06 firing at 1 0000C (N/mm2) shrinkage after 24 hours at 1000or -0.75 -1.83 at 12500C -1.1 -3.25 These figures show that the fibrous articles produced according to the invention with monoaluminium phosphate solution have better properties than the reference sample.
In addition, it was found that the gas permeability of the fibrous material according to the invention remained practically unchanged.
EXAMPLE 2 The method described above was repeated but a slurry of fibres was used which contained only 30 kg of the fibres used in Example 1 in 1 800 litres of water. From this a fibrous material in the form of a mat was produced using the method of Example 1, and the mat was soaked with 7 litres of the monoaluminium phosphate solution used in Example 1. After heat treatment at 4500C a very stable mat was obtained.
EXAMPLE 3 The method of Example 1 was repeated but ceramic fibres were used which contained 95% by weight Al203 and 5% by weight SiO2 and had a diameter of 1 to 2 ssm and a length of 1 to 2 mm. A mat with excellent mechanical properties was obtained.
EXAMPLE 4 In this Example ground fibres were used which had a diameter of 1 to 2 um and a length of 200 to 300 ,um. This resulted in a mat with a somewhat lower density and excellent gas permeability.
EXAMPLE 5 Using the method of Example 2 a mat was produced from ceramic fibres with 62% by weight At203 and 38% by weight SiO2. The mat thus obtained was heat treated for two hours at 4400C and after firing for two hours at 1 0000C it exhibited excellent gas permeability and good mechanical properties.
EXAMPLE 6 The method of Example 2 was repeated, starting with a suspension of 35 kg of the fibres used in Example 2 in 1600 litres of water. To this were added 1.5 kg starch and 0.75 kg solid finely ground sodium polyphosphate. The fibre suspension thus produced was immediately poured onto the sieve.
After soaking with the monoaluminium phosphate solution and heat treating at a temperature of 400"C a fibrous material was produced in mat form with a somewhat lower porosity but improved mechanical properties.
EXAMPLE 7 The method of Example 6 was repeated, but 0.75 kg solid finely ground sodium polyphosphate was added not to the fibre suspension but to the monoaluminium phosphate solution used for soaking.
This also produced a fibrous mat with lower porosity but with better adhesion of the individual fibres to each other after firing the mat at 95O0C.

Claims (14)

1. A process for the production of a heat-insulating bonded fibrous article from fibrous material in which the fibrous material is shaped and then wetted with an aqueous monoaluminium phosphate solution and heat treated at a temperature of at least 4000 C.
2. A process as claimed in Claim 1 in which the fibrous material comprises ceramic fibres.
3. A process as claimed in Claim 1 in which the fibrous material is wetted with a 20 to 50% by weight aqueous monoaluminium phosphate solution.
4. A process as claimed in any of Claims 1 to 3 in which after the heat treatment the fibrous material is fired at a temperature of 800 to 1 4000C.
5. A process as claimed in any one of the preceding claims in which, prior to the heat treatment, the fibrous material is dried.
6. A process as claimed in any one of the preceding claims in which prior to bonding the fibrous material is completely soaked with the monoaluminium phosphate solution and the excess solution is then removed.
7. A process as claimed in any one of Claims 1 to 5 in which the fibrous material is bonded and then completely soaked with the aqueous monoaluminium phosphate solution and the excess solution is then removed.
8. A process as claimed in any one of the preceding claims in which the monoaluminium phosphate solution contains a minor proportion of sodium polyphosphate.
9. A process as claimed in any one of Claims 1 to 7 in which the article is formed containing sodium polyphosphate and then wetted with the aqueous monoaluminium phosphate solution.
10. A process for the production of a heat insulating bonded fibrous article substantially as specifically herein described with reference to any one of the examples.
11. A heat-insulating bonded fibrous article, produced by a process as claimed in any one of the preceding claims.
12. An article as claimed in Claim 11 when in use as a heat insulation for a pipe through which gas flows at a high pressure and/or high temperature and/or high speed.
13. An article as claimed in Claim 11 when in use as a lining for reaction chambers, such as furnaces, having an acidic atmosphere.
14. An article as claimed in Claim 11 when in use as a lining subject to wear in metallurgical containers.
GB8018808A 1979-06-11 1980-06-09 Process for the production of heat-insulating bonded fibrous articles Expired GB2052472B (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
DE19792923586 DE2923586A1 (en) 1979-06-11 1979-06-11 METHOD FOR PRODUCING HEAT-INSULATING, IN PARTICULAR CERAMIC, FASTENED FIBERBODY, FIBERBODY PRODUCED BY THE METHOD AND THE USE THEREOF

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GB2052472A true GB2052472A (en) 1981-01-28
GB2052472B GB2052472B (en) 1983-02-09

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GB8018808A Expired GB2052472B (en) 1979-06-11 1980-06-09 Process for the production of heat-insulating bonded fibrous articles

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BE (1) BE883683A (en)
DE (1) DE2923586A1 (en)
FR (1) FR2458522A1 (en)
GB (1) GB2052472B (en)
IT (1) IT1144065B (en)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2499975A1 (en) * 1981-02-16 1982-08-20 Didier Werke Ag PROFILES WITH HIGH MECHANICAL STABILITY AT HIGH TEMPERATURES, PROCESS FOR THEIR MANUFACTURE AND USE
EP0522437A2 (en) * 1991-07-02 1993-01-13 Deutsche Rockwool Mineralwoll-GmbH Molded articles made of mineral wool
FR2690439A1 (en) * 1992-04-24 1993-10-29 Fumisterie Indle Entreprises Low cement content insulating refractory concrete - capable of phosphate bonding, useful for high temp. linings

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3230638A1 (en) * 1982-08-18 1984-02-23 Chemische Fabrik Budenheim Rudolf A. Oetker, 6501 Budenheim Agent for preventing efflorescences on cement products
DE3521467C3 (en) * 1985-06-14 1994-11-17 Gruenzweig & Hartmann Montage Pipe for piping hot gases

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE1117031B (en) * 1956-11-02 1961-11-09 L O F Glass Fibers Company Process for the production of a temperature-resistant article from silicon-containing fibers and a binder
US3336716A (en) * 1963-07-10 1967-08-22 Johns Manville Furnace combustion chamber with a transverse composition differential
DE2730868B2 (en) * 1977-07-08 1980-01-24 Chemische Fabrik Budenheim Rudolf A. Oetker, 6501 Budenheim Cold-curing ceramic binder system and its use
DK142906B (en) * 1977-11-03 1981-02-23 Skamol Skarrehage Molerverk As Light, refractory insulating plate-shaped material.

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2499975A1 (en) * 1981-02-16 1982-08-20 Didier Werke Ag PROFILES WITH HIGH MECHANICAL STABILITY AT HIGH TEMPERATURES, PROCESS FOR THEIR MANUFACTURE AND USE
EP0522437A2 (en) * 1991-07-02 1993-01-13 Deutsche Rockwool Mineralwoll-GmbH Molded articles made of mineral wool
EP0522437A3 (en) * 1991-07-02 1993-06-09 Deutsche Rockwool Mineralwoll-Gmbh Molded articles made of mineral wool
FR2690439A1 (en) * 1992-04-24 1993-10-29 Fumisterie Indle Entreprises Low cement content insulating refractory concrete - capable of phosphate bonding, useful for high temp. linings

Also Published As

Publication number Publication date
DE2923586A1 (en) 1980-12-18
IT8048859A0 (en) 1980-06-02
BE883683A (en) 1980-10-01
GB2052472B (en) 1983-02-09
FR2458522A1 (en) 1981-01-02
IT1144065B (en) 1986-10-29

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PCNP Patent ceased through non-payment of renewal fee