GB2093015A - Dry composition for use in a fibre spraying composition - Google Patents

Dry composition for use in a fibre spraying composition Download PDF

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Publication number
GB2093015A
GB2093015A GB82043319A GB8204319A GB2093015A GB 2093015 A GB2093015 A GB 2093015A GB 82043319 A GB82043319 A GB 82043319A GB 8204319 A GB8204319 A GB 8204319A GB 2093015 A GB2093015 A GB 2093015A
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GB
United Kingdom
Prior art keywords
weight
parts
composition
bonding agent
fibres
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.)
Withdrawn
Application number
GB82043319A
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Didier Werke AG
Original Assignee
Didier Werke AG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Didier Werke AG filed Critical Didier Werke AG
Publication of GB2093015A publication Critical patent/GB2093015A/en
Withdrawn legal-status Critical Current

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • 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
    • C04B28/34—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 cold phosphate binders
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F27—FURNACES; KILNS; OVENS; RETORTS
    • F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
    • F27D1/00—Casings; Linings; Walls; Roofs
    • F27D1/0003—Linings or walls
    • F27D1/0006—Linings or walls formed from bricks or layers with a particular composition or specific characteristics
    • F27D1/0009—Comprising ceramic fibre elements
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00034—Physico-chemical characteristics of the mixtures
    • C04B2111/00146—Sprayable or pumpable mixtures
    • C04B2111/00155—Sprayable, i.e. concrete-like, materials able to be shaped by spraying instead of by casting, e.g. gunite
    • 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
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00482—Coating or impregnation materials
    • C04B2111/00551—Refractory coatings, e.g. for tamping
    • 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
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/20—Resistance against chemical, physical or biological attack
    • C04B2111/28—Fire resistance, i.e. materials resistant to accidental fires or high temperatures

Abstract

A dry composition for use in a spraying composition for producing heat-resistant or refractory linings comprises 100 parts by weight ceramic fibres in loosened form, 2 to 20 parts by weight clay and/or other conventional refractory constituents, 0 to 10 parts by weight fire clay powder, 2 to 8 parts by weight phosphate bonding agent, calculated as P2O5 and 1 to 4 parts by weight solid organic bonding agent.

Description

SPECIFICATION Dry composition for use in a fibre spraying composition The invention relates to a dry composition for use in fibre spraying compositions for producing refractory or heat-resistant linings.
It is known to use ceramic fibres in so called fibre spraying compositions. For this purpose ceramic fibres and large quantities of water are first mixed and then either sprayed on to walls or on to ceilings with the aid of a spraying device to produce a refractory or heat-resistant lining or they may be sprayed into hollow spaces.
DE-AS 26 18 81 3 discloses fibre spraying compositions which, in addition to a large proportion of inorganic fibres and low proportions of bonding agent and other inorganic additives, additionally contain a chemical additive bonder, whereby these fibre spraying compositions contain additionally 5 to 20% by weight of an oil to avoid the formation of dust.
In another method, dry ceramic fibres and water are fed separately to the head of a spraying device, mixed with one another in the head of this spraying device and then sprayed on to walls or ceilings or sprayed into hollow spaces. Furthermore, it is also known to add further additives such as bonding agent and other conventional additives to the slurry described above of ceramic fibres in water.
Due to the large quantities of water which are required when spraying it is, however, difficult homogeneously to mix these additives, such as a bonding agent and other conventional additives, with the fibres in the spraying device and to obtain a sprayed composition which adheres adequately to the surface on which it is sprayed.
It is an object of the present invention to provide a dry composition or mixture for use as a fibre spraying composition which can be applied to walls of both metal piate and of brickwork in a layer of a thickness of 30 cm. It is a further object that the composition should be capable of being immediately heated to high temperatures without having to be subjected to a prior drying process.
According to the present invention there is provided a dry composition for use in spraying compositions for the production of refractory or heat-resistant linings containing the following components in an intimately mixed state: a) 100 parts by weight ceramic fibres, b) 2 to 20 parts by weight clay and/or Awl203 and/or Si02 and/or aluminium hydroxides and/or magnesia and/or titanium dioxide and/or chromium oxide, c) 0 to 10 parts by weight fire clay powder, d) 2 to 8 parts by weight of a phosphate bonding agent, calculated as P2Os, and e) 1 to 4 parts by weight of a solid organic bonding agent.
The ceramic fibres in the composition in accordance with the invention can be all the conventional fibres of this type, e.g. mineral fibres, such as rock wool, or fibres based on aluminium silicate, preferably with a particularly high Awl203 content in the region of 45 to 95% by weight. Naturally mixtures of different ceramic fibres can also be used.The fibres are, however, preferably based on Al203 and Si02 with at least 40% by weight Awl203 and are preferably capable of being used at temperatures in excess of 1 100'C. This will in general exclude inorganic fibres based on, for instance, basalt, slag and glass and natural asbestos fibres whose use temperature is below 11 00 C, but such fibres may be used as a subsidiary component in addition to those whose use temperature is above 11 00 C.
Advantageously the ceramic fibres are present in loosened form. For this purpose, commercial fibres are put in the state in which they are usually delivered in an impact mixer (e.g. a Turbulent-Rapid Mixer manufactured by Drais), in which the fibres which are commonly delivered as fibre bundles are converted into loosened fibres. Such an impact mixer comprises a mixing unit with rapidly rotating knife heads by means of which any agglomerates which may be present in conventional fibres, which are frequently partially present in a strongly compressed form, are loosened, without the fibres being thereby unacceptably crushed or comminuted.
The clay present in the composition in accordance with the invention can be a conventional clay or a special bonding clay, e.g. bentonite. This clay is preferably used in an amount of 5 to 20 parts by weight 10 to 100 parts by weight of the ceramic fibres and advantageously 8 to 1 5 parts by weight clay are used.
The components which may be present in the composition in addition to or instead of the clay are, in accordance with the invention, Awl203 and/or Si02 and/or magnesia and/or titanium dioxide and/or chromium oxide, all of which are preferably present in very finely divided form, and/or aluminium hydroxides. These are components whose use is known in the refractory field. The term "very finely divided" used in conjunction with the components referred to above means that these components are present in a very finely ground state or in the colloidal state.
The very finely divided refractory materials preferably have a grain size of less than 50 ym, more preferably less than 10 ym. Particularly when using such materials in the colloidal state, such as colloidal SiO2 or colloidal aluminium oxide, it is possible to use only small quantities of bonding agent, that is to say close to the lower threshold value of 1 part by weight of an organic bonding agent and 2 parts by weight of a phosphate bonding agent. The use of approximately the same parts by weight of phosphate bonding agent and methyl cellulose as organic bonding agent is particularly preferred.It is also particularly advantageous to use a mixture of clay and one or more of the other refractory components referred to above, the quantity of these other refractory components being preferably 1 to 3 parts by weight and the remainder clay so that the amount stipulated in the main claim of 2 to 20 parts by weight of refractory components is present. Additionally 0 to 10 parts by weight fire clay powder are present in the composition in accordance with the invention. This can be any desired finely ground fire clay and preferably the maximum grain size of the powder is < 63 ,um and particularly preferably < 44 ,um.
Additionally 2 to 8 parts by weight and preferably 3 to 6 parts by weight of phosphate bonding agent are present in the composition in accordance with the invention, the given quantities in parts by weight referring to P205 in the bonding agent or mixture of bonding agents. An example of suitable phosphate bonding agents is sodium polyphosphate with a degree of polymerisation of n24 and preferably with a degree of polymerisation of 6 to 10. This sodium polyphosphate is used in solid form. A further phosphate bonding agent is monaluminium phosphate that is a commercial product available in solid ground form.
A solid organic bonding agent is present in the composition in accordance with the invention.
For this purpose all organic bonding agents commonly used in this field may be used, for instance methyl cellulose, sulphite lye or waste or molasses.
In the production of the dry composition in accordance with the invention the individual components are put into a mixer in any desired order. For this purpose a conventional mixer or an impact mixer as was described above can be used. Instead of using fibres which have already been loosened for producing the compositions in accordance with the invention, commercial ceramic fibres can also be put into such an impact mixer together with the other components and the loosening of the ceramic fibres and the intimate mixing with the other components carried out in it simultaneously.
The dry compositions in accordance with the invention can be sprayed with a conventional spraying machine of the type which is common in concrete processing technology. For this, the water necessary for setting is fed to the spray nozzle. Since the compositions in accordance with the invention are in the form of an intimate mixture with bonding agents homogeneously distributed within them the quantity of water which is required is much less than with known dry compositions which can also be sprayed in this manner.
Certain specific embodiments of the invention will now be described in more detail by way of example with reference to the following Examples.
In the Examples ceramic fibres A and B were used which had the following chemical composition: Fibres A) Al203 = 47%; Si02 = 53% Fibres B) Awl203 = 95%; Si02 = 5%.
Example I The following composition was used: Parts by weight Ceramic fibres A 100 Bonding clay (with 35% Awl203) 10 Fire clay powder < 63 jum 10 Solid sodium polyphosphate 6 Solid methyl cellulose 2 These compounds were thoroughly mixed for 20 minutes in an Eirich mixer.
The dry mixture was sprayed in a spraying machine, to the nozzle of which it was fed by pressurized air and there mixed with water also fed to the nozzle.
Sprayed thicknesses on perpendicular walls of metal plate of 30 cm could be produced with this composition. The sprayed mass could be heated immediately without particular drying.
Such a sprayed on mass had the properties given in the following table, the different columns containing the properties after heating at a given temperature for a given period of time: Table I Freshly 300"C 1000"C 1200"C State sprayed 8 h 12 h 24 h Weight per unit volume (g/cm3) 0.86 0.57 0.56 0.65 Cold bending strength (N/mm2) n.m. 0.5 0.6 1.3 Cold compression strength (N/mm2) n.m. 0.5 1.0 2.3 Thermal conductivity (W/m OK) at 400"C 0.15 at 600"C 0.18 at 1000on 0.20 at 1100 C0.21 n.m. = not measurable.
Example 2 The following composition was used: Parts by weight Ceramic fibres B 75 Ceramic fibres A 25 Bonding clay with 35% Awl203 10 Solid monoaluminium phosphate 6 Solid sodium polyphosphate 2 Methyl cellulose 3 First the ceramic fibres were converted in an impact mixer for 1 5 minutes into loosened fibres. Then the other components were added and mixed for a further 3 minutes in the impact mixer.
After processing in accordance with the method of Example 1 the following properties were measured in the sprayed mass: Table II Freshly 300"C 1000"C 1400"C State sprayed 8 h 1 2 h 24 h Weight per unit volume (g/cm3) 0.6 0.4 0.4 0.5 Cold bending strength (N/mm2) n.m. 0.4 0.4 0.7 Cold compression strength (N/mm2) n.m. 0.5 0.7 2.0

Claims (5)

1. Dry composition for use in spraying compositions for the production of refractory or heatresistant linings containing the following components in an intimately mixed state: a) 100 parts by weight ceramic fibres, b) 2 to 20 parts by weight clay and/or Al203 and/or Si02 and/or aluminium hydroxides and/or magnesia and/or titanium dioxide and/or chromium oxide, c) 0 to 10 parts by weight fire clay powder, d) 2 to 8 parts by weight of a phosphate bonding agent, calculated as P205, and e) 1 to 4 parts by weight of a solid organic bonding agent.
2. Composition as claimed in Claim 1 in which the ceramic fibres are present in loosened form.
3. Composition as claimed in Claim 1 or Claim 2 in which the clay is bentonite.
4. Composition as claimed in any one of Claims 1 to 3 in which the phosphate bonding agent is sodium polyphosphate or monaluminium phosphate.
5. Dry composition for use in spraying compositions for the production of refractory or heat resistant linings substantially as specifically herein described with reference to any one of the accompanying examples.
GB82043319A 1981-02-16 1982-02-15 Dry composition for use in a fibre spraying composition Withdrawn GB2093015A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
DE3105533A DE3105533C2 (en) 1981-02-16 1981-02-16 Dry matter for use as fiber injection molding compound

Publications (1)

Publication Number Publication Date
GB2093015A true GB2093015A (en) 1982-08-25

Family

ID=6124955

Family Applications (1)

Application Number Title Priority Date Filing Date
GB82043319A Withdrawn GB2093015A (en) 1981-02-16 1982-02-15 Dry composition for use in a fibre spraying composition

Country Status (12)

Country Link
JP (1) JPS57145082A (en)
BE (1) BE892034A (en)
DD (1) DD202281A5 (en)
DE (1) DE3105533C2 (en)
FR (1) FR2499968A1 (en)
GB (1) GB2093015A (en)
IT (1) IT8247786A0 (en)
NL (1) NL8200604A (en)
NO (1) NO820439L (en)
PL (1) PL235101A1 (en)
SE (1) SE8200857L (en)
ZA (1) ZA821014B (en)

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1985001676A1 (en) * 1983-10-17 1985-04-25 Manville Service Corporation Insulation system
US4547403A (en) * 1983-10-17 1985-10-15 Manville Service Corporation Method for applying a layer of fiber on a surface
US4640848A (en) * 1985-08-26 1987-02-03 Kennecott Corporation Spray-applied ceramic fiber insulation
US4664969A (en) * 1986-05-30 1987-05-12 Manville Corporation Method for spray applying a refractory layer on a surface and the layer produced thereby
US4673594A (en) * 1984-10-12 1987-06-16 Manville Service Corporation Method for applying a layer of fiber on a surface and a refractory material produced thereby
US4737192A (en) * 1983-10-17 1988-04-12 Manville Service Corporation Refractory binder, method for making same, and product produced thereby
US4770707A (en) * 1984-10-12 1988-09-13 Manville Corporation Method for forming a layer of refractory fibers on a surface and material produced thereby
US4822679A (en) * 1985-08-26 1989-04-18 Stemcor Corporation Spray-applied ceramic fiber insulation
US4833025A (en) * 1988-03-07 1989-05-23 Manville Corporation Method for applying a refractory layer on a surface and the layer produced thereby
CN107721397A (en) * 2017-11-01 2018-02-23 安徽马钢耐火材料有限公司 A kind of pink fused alumina chamotte and preparation method thereof

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2133194A5 (en) * 1971-04-13 1972-11-24 Produits Refractaires
DE2230429A1 (en) * 1972-06-22 1974-01-10 Vyzk Ustav Stavebnich Hmot V B Large fibre-board prodn - using a starch-phosphoric acid react prod as binder
FR2349551A1 (en) * 1976-04-30 1977-11-25 Alsacienne Atom Porous refractory mouldings resistant to molten aluminium or iron - contain ceramic fibres and e.g. alumina, bonded by metal phosphate

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1985001676A1 (en) * 1983-10-17 1985-04-25 Manville Service Corporation Insulation system
US4547403A (en) * 1983-10-17 1985-10-15 Manville Service Corporation Method for applying a layer of fiber on a surface
US4737192A (en) * 1983-10-17 1988-04-12 Manville Service Corporation Refractory binder, method for making same, and product produced thereby
US4673594A (en) * 1984-10-12 1987-06-16 Manville Service Corporation Method for applying a layer of fiber on a surface and a refractory material produced thereby
US4770707A (en) * 1984-10-12 1988-09-13 Manville Corporation Method for forming a layer of refractory fibers on a surface and material produced thereby
US4640848A (en) * 1985-08-26 1987-02-03 Kennecott Corporation Spray-applied ceramic fiber insulation
US4822679A (en) * 1985-08-26 1989-04-18 Stemcor Corporation Spray-applied ceramic fiber insulation
US4664969A (en) * 1986-05-30 1987-05-12 Manville Corporation Method for spray applying a refractory layer on a surface and the layer produced thereby
US4833025A (en) * 1988-03-07 1989-05-23 Manville Corporation Method for applying a refractory layer on a surface and the layer produced thereby
CN107721397A (en) * 2017-11-01 2018-02-23 安徽马钢耐火材料有限公司 A kind of pink fused alumina chamotte and preparation method thereof

Also Published As

Publication number Publication date
PL235101A1 (en) 1982-10-11
JPS57145082A (en) 1982-09-07
NL8200604A (en) 1982-09-16
BE892034A (en) 1982-05-27
DE3105533A1 (en) 1982-08-19
DE3105533C2 (en) 1982-10-28
DD202281A5 (en) 1983-09-07
SE8200857L (en) 1982-08-17
ZA821014B (en) 1983-01-26
IT8247786A0 (en) 1982-02-12
FR2499968A1 (en) 1982-08-20
NO820439L (en) 1982-08-17

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WAP Application withdrawn, taken to be withdrawn or refused ** after publication under section 16(1)