GB2176773A - Abrasion resistant refractory castable composition - Google Patents
Abrasion resistant refractory castable composition Download PDFInfo
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- GB2176773A GB2176773A GB8615260A GB8615260A GB2176773A GB 2176773 A GB2176773 A GB 2176773A GB 8615260 A GB8615260 A GB 8615260A GB 8615260 A GB8615260 A GB 8615260A GB 2176773 A GB2176773 A GB 2176773A
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- alumina
- refractory
- silica
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- 239000000203 mixture Substances 0.000 title claims abstract description 48
- 238000005299 abrasion Methods 0.000 title abstract description 35
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims abstract description 83
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims abstract description 51
- 239000000377 silicon dioxide Substances 0.000 claims abstract description 40
- 239000004568 cement Substances 0.000 claims abstract description 23
- XFWJKVMFIVXPKK-UHFFFAOYSA-N calcium;oxido(oxo)alumane Chemical compound [Ca+2].[O-][Al]=O.[O-][Al]=O XFWJKVMFIVXPKK-UHFFFAOYSA-N 0.000 claims abstract description 5
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 12
- 239000004927 clay Substances 0.000 claims description 2
- 238000005496 tempering Methods 0.000 claims description 2
- 238000012546 transfer Methods 0.000 abstract description 4
- 238000000034 method Methods 0.000 abstract description 2
- 208000035874 Excoriation Diseases 0.000 description 33
- 238000005266 casting Methods 0.000 description 26
- 238000010438 heat treatment Methods 0.000 description 13
- 239000013078 crystal Substances 0.000 description 7
- 238000001035 drying Methods 0.000 description 7
- 229910052593 corundum Inorganic materials 0.000 description 6
- 230000000694 effects Effects 0.000 description 5
- 238000012360 testing method Methods 0.000 description 5
- 239000010431 corundum Substances 0.000 description 4
- 238000011156 evaluation Methods 0.000 description 4
- 238000007792 addition Methods 0.000 description 3
- 230000000052 comparative effect Effects 0.000 description 3
- 238000002474 experimental method Methods 0.000 description 3
- 238000009434 installation Methods 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- 229910000873 Beta-alumina solid electrolyte Inorganic materials 0.000 description 2
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N Iron oxide Chemical compound [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 2
- KKCBUQHMOMHUOY-UHFFFAOYSA-N Na2O Inorganic materials [O-2].[Na+].[Na+] KKCBUQHMOMHUOY-UHFFFAOYSA-N 0.000 description 2
- 229910019142 PO4 Inorganic materials 0.000 description 2
- 238000004873 anchoring Methods 0.000 description 2
- 238000009826 distribution Methods 0.000 description 2
- 238000004231 fluid catalytic cracking Methods 0.000 description 2
- 239000010452 phosphate Substances 0.000 description 2
- 125000002467 phosphate group Chemical group [H]OP(=O)(O[H])O[*] 0.000 description 2
- 239000011819 refractory material Substances 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 229910001845 yogo sapphire Inorganic materials 0.000 description 2
- 239000005995 Aluminium silicate Substances 0.000 description 1
- 229910000519 Ferrosilicon Inorganic materials 0.000 description 1
- CDBYLPFSWZWCQE-UHFFFAOYSA-L Sodium Carbonate Chemical compound [Na+].[Na+].[O-]C([O-])=O CDBYLPFSWZWCQE-UHFFFAOYSA-L 0.000 description 1
- 239000002253 acid Substances 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- ILRRQNADMUWWFW-UHFFFAOYSA-K aluminium phosphate Chemical compound O1[Al]2OP1(=O)O2 ILRRQNADMUWWFW-UHFFFAOYSA-K 0.000 description 1
- 229910000323 aluminium silicate Inorganic materials 0.000 description 1
- 235000012211 aluminium silicate Nutrition 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
- 229910001570 bauxite Inorganic materials 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 239000011449 brick Substances 0.000 description 1
- 239000006227 byproduct Substances 0.000 description 1
- 239000003054 catalyst Substances 0.000 description 1
- 238000004523 catalytic cracking Methods 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 229940000425 combination drug Drugs 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 230000003628 erosive effect Effects 0.000 description 1
- 239000000835 fiber Substances 0.000 description 1
- 230000009969 flowable effect Effects 0.000 description 1
- 229910021485 fumed silica Inorganic materials 0.000 description 1
- 230000001771 impaired effect Effects 0.000 description 1
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 description 1
- 230000001788 irregular Effects 0.000 description 1
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 description 1
- 229910052850 kyanite Inorganic materials 0.000 description 1
- 239000010443 kyanite Substances 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 239000000047 product Substances 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 230000009257 reactivity Effects 0.000 description 1
- 238000007670 refining Methods 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 1
- 229910010271 silicon carbide Inorganic materials 0.000 description 1
- -1 silicon nitrides Chemical class 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 239000004094 surface-active agent Substances 0.000 description 1
- 230000002195 synergetic effect Effects 0.000 description 1
- 239000011882 ultra-fine particle Substances 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
- C04B35/63—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
- C04B35/6303—Inorganic additives
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- 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
- C04B28/02—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 hydraulic cements other than calcium sulfates
- C04B28/06—Aluminous cements
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/10—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on aluminium oxide
- C04B35/101—Refractories from grain sized mixtures
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/14—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silica
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/66—Monolithic refractories or refractory mortars, including those whether or not containing clay
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/3217—Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/34—Non-metal oxides, non-metal mixed oxides, or salts thereof that form the non-metal oxides upon heating, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/3418—Silicon oxide, silicic acids or oxide forming salts thereof, e.g. silica sol, fused silica, silica fume, cristobalite, quartz or flint
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
- Y02W30/00—Technologies for solid waste management
- Y02W30/50—Reuse, recycling or recovery technologies
- Y02W30/91—Use of waste materials as fillers for mortars or concrete
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Materials Engineering (AREA)
- Structural Engineering (AREA)
- Organic Chemistry (AREA)
- Inorganic Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Ceramic Products (AREA)
- Compositions Of Oxide Ceramics (AREA)
Abstract
A refractory composition characterized by relatively high abrasion resistance, good flowability and long working time, comprises 0.5 to 5% by weight of volatilized silica, 3.0 and 15% by weight of -65 mesh alumna, and 10 to 40% by weight of calcium aluminate cement, the balance being a refractory agreggate such as silica, alumina or fireclay. The composition may be used in lining transfer lines employed in petrochemical processes.
Description
SPECIFICATION
Abrasion resistant refractory composition
This invention is concerned with refractory compositions characterized by high abrasion resistance and, in particular, with such compositions which may be used as refractory castables.
Refractory castables are hydraulic setting compositions. They comprise granular refractory aggregates and chemical binders. The refractory castables are shipped in dry form and when mixed with water to the desired consistency, may be poured like concrete, tamped or rammed into place, troweled or applied with an air gun. Refractory castables take a strong hydraulic set at room temperatures and maintain good strength until the desired ceramic bond is developed as the temperature is increased. Castables are specially suited for furnace linings of irregular contours, for patching brick work and for casting special shapes which may be urgently required.
Numerous castable compositions are known, with each of the known compositions having different properties, making each one useful for different applications.
One such application involves the use of refractory castables in lining transfer lines employed in fluid catalytic cracking units used in petrochemical processes. In such units, highly abrasive catalysts travel at high speeds, thereby creating extreme erosion potential throughout the catalytic cracking unit. In such units, early abrasion resistant linings were formed from phosphate bonded refractories, which required extensive anchoring and hand ramming to install. To reduce the expense of installing phosphate bonded refractories, the refining industry began using castables with field additions of stainless steel fibers which required less anchoring on the metal shell, and which could be poured relatively quickly. Although the foregoing improved on the time and cost of installation, increased abrasion resistance was desired.
Abrasion resistant linings in petrochemical vessels are typically chemically bonded or cement bonded refractory compositions. Abrasion resistance is generally obtained by utilizing a strong, dense refractory grain such as calcined fireclay, and a strong bond consisting of aluminium orthophosphate, or calcium aluminate cement. In the case of cement, the abrasion resistant bond is achieved by using large amounts of cement, or a combination of fumed silica, cement in amounts less than ten percent, and a surface active agent which allows flow at low water contents. Improved density, which is achieved by casting at low water contents, results in a highly abrasion resistant bond at low cement levels.
Trying to effect further economies in installation, operators of the fluid catalytic cracking units started casting larger sections of transfer lines, eliminating the assembly of many smaller sections. The refractory castables used on the transfer lines were made with relatively fast setting cements, and did not stay flowable a sufficient time for use in such applications. Refractory manufacturers reformulated their abrasion resistant castables to incorporate casting grade cements to lengthen working time. These products provided the flowability and working time needed, but strengths and abrasion resistance were often lower than similar mixes containing regular calcium aluminate cement.
We have now developed refractory compositions which are characterised by good flowability and relatively long working times and by improved densities, strength and abrasion resistance.
According to the present invention, there is provided a refractory composition which comprises 0.5 to 5% by weight of volatilized silica, 3.0 to 15% by weight of -65 mesh alumina, and 10 to 40% by weight of calcium aluminate cement, the balance being a refractory aggregate.
All mesh sizes in this specification are in the Tyler standard series.
Such a composition is a dry composition suitable for shipment, for use as a refractory castable, the composition additionally comprises sufficient tempering water to give the desired consistency.
The refractory aggregate is preferably silica, alumina or fireclay.
The composition preferably comprises about 2% by weight of the volatilized silica and about 8% by weight of the -65 mesh alumina.
In order that the invention may be more fully understood, the following examples and comparative experiments are given by way of illustration only. All the percentages are by weight, unless otherwise indicated.
Mixes N, P, Q, R, S, T, U, V, W, X, Y, Z and AA below are examples of the invention; all other mixes are comparative experiments.
Examples and comparative experiments
A first series of mixes was prepared (see Table I below). This mix series shows the effects of
increasing the fine alumina content from 0 to 15% in a fireclay castable. As may be observed,
density, strength and abrasion resistance improve as the alumina content increases. Abrasion
resistance improvement from 8.4 cc loss in the mix having 0% alumina to 7.0 cc loss in the mix
having 15% alumina, is significant for a type of refractory which has relativey good abrasion resistance before the alumina addition.Fine synthetic aluminas are commonly used in the refractory industry to improve the refractoriness of the bonding portion of the refractory and as a source of fine material to ensure that the refractory has a proper grain size distribution. TABLE I
Mixes containing A-17 Reactive Alumina Without Volatilized Silica
Mix Designation:B C D E
Mix:
Calcined Super Duty Flint, -3 mesh 50% 50% 50% 50%
Calcined Super Duty Flint, BMF 20 17 11 5
A-17 Reactive Alumina, -325 mesh 0 3 9 15
CA-25 C Casting Grade Cement 30 30 30 30
Casting Water Required, %: 8.7 8.6 8.4 8.2
Bulk Density, pcf (kg/cu. m)
After Drying at 250 F (121 C): 144 (2304) 145 (2320) 150 (2400) 152 (2432)
After Heating 5 Hrs. at 1500 F (816 C) 137 (2192) 139 (2224) 141 (2256) 145 (2320)
Cold Crushing Strenght After Heating 5 Hrs. at 1500 F (816 C), psi (kPa): 14,260 15,940 16,880 16,900 (98323) (109906) (116388) (116526)
Abrasion Test (ASTM C-704)
Volume Loss of Samples Heated 5 Hrs. at 1500 F (816 C), cu. cm: 8.4 7.2 7.1 7.0 A second series of mixes were made to determine the effect of adding 0 to 5% volatilized silica to the same abrasion resistant fireclay castable. Volatilized silica additions of 0.5% and 2% resulted in improved densities, strength and abrasion resistance. At volatilized silica levels of 3% and 5%, the mix became sticky and did not flow as well as previously. Densities and strength suffered, but the improved abrasion resistance is maintained. Volatilized silica is a sub-micron, amorphous by-product of ferrosilicon production and is a well known refractory raw material. It is used primarily as a source of ultrafine particles, as a source of reactive silica and as an additive to improve flow properties. As Table II illustrates, only small amounts can be used in cement containing mixes or flow properties would be adversely affected.
TABLE II
Mixes Containing Volatilized Silica Without Fine Alumina
Mix Designation. B F G H J
Calcined Super Duty Flint, -3 mesh 50% 50% 50% 50% 50%
Calcined Super Duty Flint, BMF 20 19.5 18 17 15
Volatilized Silica -- 0.5 2 3 5
CA-25 C Casting Grade Cement 30 30 30 30 30
Casting Water Required, %: 8.7 8.0 7.9 7.8 7.6
Casting Characteristics: At volatilized silica levels up to 2%, the mix flowed well during vibration casting. At a 3% volatilized silica level, the mix flowed well, but was sticky.
At a 5% volatilized silica level, the mix had poor flow during casting, was very sticky to the point that handling was difficult, and dried out quickly, making large installations difficult.
Bulk Density, pcf (kg/cu.m)
After Drying at 250 F (121 C): 144(2304) 147(2325) 147(2325) 145(2320)
After Heating 5 Hrs. at 1500 F (815 C): 137(2192) 140(2240) 140(2240) 138(2208) 138(2208)
Cold Crushing Strength after
Heating 5 Hrs. at 1500 F 14,260 16,800 16,290 12,730 11,420 (816 C) psi (kPa): (98323) (115836) (112320) (87773) (78741)
Abrasion Test (ASTM C-704)
Volume Loss of Samples Heated 5 Hrs. at 1500 F (816 C), cu cm: 8.4 6.8 6.4 6.1 6.3 A third series of mixes were made to determine the effects of adding volatilized silica to a fireclay castable containing fine alumina. As the alumina is replaced by up to 2% silica, density, strength and abrasion resistance improve. At a silica level of 3%, the mix becomes sticky and flow is impaired. The abrasion resistance, however, continues to improve.Mix P has outstanding abrasion resistance, but mix N is preferred because of its superior flowability, a necessary property when the composition is employed as a refractory castable for use in relatively large applications. The synergistic effect of using volatilized silica and fine alumina together should be noted. The abrasion resistances of mixes N and P are superior to any of the mixes set forth in
Tables I and II, where each material was used separately.
TABLE III
Evaluation of Alimina/Silica Ratio when Fine Alumina + Volatilized Silica Equals 10%
Mix Designation: K L N P
Mix:
Calcined Super Duty Flint, -3 mesh 50% 50% 50% 50%
Calcined Super Duty Flint, BMF 10 10 10 10
A-17 Reactive Alumina, -325 mesh 10 9 8 7
Volatilized Silica -- 1 2 3
CA-25 C Casting Grade Cement 30 30 30 30
Casting Water Required, %: 9.4 8.15 8.0 8.65
Casting Characteristics: All mixes flowed well during vibration casting.
At a volatilized silica level of 3%, the mix was sticky and difficult to handle.
Bulk Density, pcf (kg/cu.m)
After Drying at 250 F (121 C): 141(2256) 148(2368) 151(2416) 141(2256)
After Geating 5 Hrs. at 1500 F (816 C): 135(2160) 140(2240) 141(2256) 136(2176)
Cold Crushing Strength After Heating 5 Hrs. at 1500 F (816 C), psi (kPa): 6,990 12,460 12,440 9,660 (48196) (85912) (85774) (66608)
Abrasion Test (ASTM C-704)
Volume Loss of Samples Heated 5 Hrs. at 1500 F (816 C) cu cm: 10.1 6.7 5.7 4.6 A fourth series of mixes were made, with each of the mixes being compounded according to the teachings of the present invention. Each of the mixes contained 2% volatilized silica and 8% fine alumina of three different types. All four mixes had high cold crushing strengths and outstanding abrasion resistance. The A-17 and A-15 reactive aluminas are almost entirely composed of fine, sintered corundum (alpha-alumina) crystals.Their high surface area and small crystal size makes them thermally reactive, that is they will further sinter or react with other compounds at relatively low temperatures. T-61 tabular alumina is also essentially 100% corundum crystals, but this material has been fired to a high temperature, resulting in coarse, tabletshaped, non-reactive crystals. A-2 calcined alumina is about 90% corundum crystals and 10% beta-alumina (Na20. 11 Al2O3) crystals. The thermal reactivity of the A-2 calcined alumina is between tabular alumina and reactive alumina. Table VIII lists the various properties of these aluminas.
TABLE IV
Alumina Type Evaluation
Mix Designation: N Q R S
Mix:
Calcined Super Duty Flint, -3 mesh 50% 50% 50% 50%
Calcined Super Duty Flint, BMF 10 10 10 10
A-17 Reactive Alumina, -325 mesh 8 -- -- -
A-15 Reactive Alumina, -325 mesh -- -- -- -
T-61 Tabular Alumina, -325 mesh -- -- 8 -
A-2 Calcined Alumina, -325 mesh -- -- -- 8
Volatilized Silica 2 2 2 2
CA-25 C Casting Grade Cement 30 30 30 30
Casting Water Required, %: 8.0 7.9 8.0 8.3
Bulk Density, pcf (kg/cu.m)
After Drying at 250 F (121 C): 151(2416) 149(2384) 150(2400) 149(2384)
After Heating 5 Hrs. at 1500 F (816 C): 141(2256) 142(2272) 142(2272) 142(2272)
Cold Crushing Strength after
Heating 5 Hrs. at 1500 F (816 C), psi (kPa): 12,440 11,320 14,410 15,960 (85774) (78051) (99357) (110044)
Abrasion Test (ASTM C-704)
Volume Loss of Samples Heated 5 Hrs. at 1500 F (816 C), cu cm: 5.7 5.3 5.6 5.4 Three further mixes were made according to the invention with 1% volatilized silica and 9% fine alumina. Mix T was based on a calcined fireclay grain. This type of mix would be used where good abrasion resistance is necessary. Mix U is based on a vitreous silica grain. This mix would be used where a combination of good abrasion resistance and low thermal conductivity are desired. Mix V is based on coarse, tabular alumina, and represents the ultimate strength and abrasion resistance. Since tabular alumina is over ten times more expensive than calcined fireclay, the increased cost may not be justified by the modest property improvements. The three mixes are intended to illustrate the types of base grains which may be used from 100% silica to a fire clay of roughly 50% silica and 45% alumina to 100% alumina.There are a variety of high alumina grains having alumina contents between fireclay and tabular alumina, such as calcined bauxitic kaolin, calcined bauxite, kyanite and andalusite, which would also work satisfactorily in this invention. In addition, non-aluminosilicates such as silicon carbide, silicon nitrides or any acid aggregate would be satisfactory.
TABLE V
Base Grain Evaluation
Mix Designation: T U V
Mix:
Calcined Super Duty Flint, -3 mesh through fines 60% -- -
Vitreous Silica, -3 mesh through fines -- 60% -
Tabular Alumina, -6 mesh through fines -- -- 60%
Calcined Super Duty Flint, BMF
A-17 Reactive Alumina, 9 9 9
Volatilized Silica 1 1 1
CA-25 C Casting Grade Cement 30 30 30
Casting Water Required, %: 8.15 7.9 8.2
Bulk Density, pcf (kg/cu.m)
After Drying at 250 F (121 C): 148(2368) 130(2080) 176(2816)
After Heating 5 Hrs. at 1500 F (816 C): 140(2240) 123(1968) 166(2656)
Cold Crushing Strength after Heating 5 Hrs. at 1500 F (816 C), (kPa): 12,460 6,890 16,770 (85912) (47507) (115692)
Abrasion Test (ASTM C-704)
Volume Loss of Samples Heated 5 Hrs. at 1500 F (816 C), cu cm: 6.7 12.6 6.5 The next series of mixes was intended to show the effects of variations of the cement content.As may be observed, as the cement content was increased from 10 to 40%, the cold crushing strength and abrasion resistance generally improved.
TABLE VI
Cement Content Evaluations Nix Designation: w X Y
Nix:
Calcined Super Duty
Flint Clay, -3 mesh 70% 50% 50%
Calcined Super Duty
Flint Clay, BMF 10 10 -
A-17 Reactive Alumina 8 8 8
Volatilized Silica 2 2 2
CA-25C Casting Grade
Cement 10 30 40
Casting Water Required, %: 8.0 8.0 9.0
Bulk Density, pcf (kg/cu.m)
After Drying at 250 F (1210C) : 138(2208) 151(2416) 151(2416)
After Heating 5 Hrs. at
15000F (816 C): 136(2176) 141(2256) 141(2256)
Cold Crushing Strength
After Heating 5 Hrs.
at 1500 F (816 C),
psi (kPa): 5,600 12,440 12,420
(38612) (85774) (85636)
Abrasion Resistance
(ASTM C-704) Volume Loss of Samples Heated 5 Hrs.
at 1500 F (8160C), Cu. cm: 14.9 5.7 5.5 The last series of mixes establishes the upper and lower limits of volatilized silica and fine
alumina contents as well as illustrates the preferred mix which was chosen for its good combi
nation of flow properties and physical properties.
TABLE VII
Fine Alumina and Volatilized Silica Ranges
with Preferred Mix Nix Designation: Z X AA
Nix:
Calcined Super Duty
Flint Clay, -3 mesh 50% 50% 50%
Calcined Super Duty
Flint Clay, BMF 4.5 10 12
A-17 Reactive Alumina,
-325 mesh 15 8 3
Volatilized Silica 0.5 2 5
CA-25C Casting Grade
Cement 30 30 30
Casting Water Required, VJ: 8.4 8.o 7.6
Casting
Characteristics: The mix containing o.5ro volatilized
silica had acceptable flow properties duripg
casting, but not as good as the mix containing 2%
volatilized silica. The mix containing 5rú volatilized silica had poor flow, was difficult to
handle because of its stickiness and dried out
quickly during casting.
Bulk Density, pcf (kg/cu.m)
After Drying at 250 F (1210C) : 154(2464) 151(2416) 149(2384) After Heating 5 Hrs.
at 1500 F (816 C): 145(2320) 141(2256) 141(2256) Cold Crushing Strength
After Heating 5 Hrs.
at 1500 F (816 C), 15,050 12,440 11,540
psi (KPa): (103770) (85774) (79568)
Abrasion Resistance (ASThi C-704) Volume Loss of
Samples Heated 5 Hrs. at 15000F (8160C), cu. cm: 6.5 5.7 4.9 TABLE VIII
Alumina Brand: A-17 A-15 T-61 A-2
Manufacturer: ALCOA
Alumina Type: Reactive Reactive Tabular Calcined
Chemical Analysis (Typical)
Alumina (Al2O3) 99.5-% 99.5-% 99.5-% 99.2-%
Silica (SiO2) 0.02 0.02 0.06 0.02
Iron Oxide (Fe2O3) 0.02 0.02 0.06 0.04
Soda (Na2O) 0.07 0.07 0.10 0.45
Ultimate Crystal Size, microns: 3-3.5 2-2.5 10+ 3-5
Mineralogical Composition
Corundum, % 100 100 100 90
Beta Alumina, % -- -- -- 10
Paritcle Size Distribution
% Finer than 60 microns: 100% 100% 100% 100%
% Finer than 40 microns: 100 100 100 100
% Finer than 20 microns: 100 100 100 100
% Finer than 10 microns: 98 98 56 86
% Finer than 5 microns: 87 90 37 74
% Finer than 1 microns: 21 24 9 9
% Finer than 0.5 microns: 12 15 2 4
Claims (7)
1. A refractory composition which comprises 0.5 to 5% by weight of volatilized silica, 3.0 to 15% by weight of -65 mesh alumina, and 10 to 40% by weight of calcium aluminate cement, the balance being a refractory aggregate.
2. A composition according to claim 1 which also comprises sufficient tempering water for the composition to be usable as a refractory castable.
3. A composition according to claim 1 or 2, in which the refractory aggregate is silica, alumina or fireclay.
4. A composition according to claim 3, in which the refractory aggregate includes 4.5 to 12% by weight of -65 mesh calcined clay.
5. A composition according to any of claims 1 to 4, which comprises substantially 2% by weight of volatilized silica.
6. A composition according to any of claims 1 to 5, which comprises substantially 8% by weight of -65 mesh alumina.
7. A refractory composition substantially as herein described with reference to Mix N, P, Q,
R, S, T, U, V, W, X, Y, Z or AA.
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US74826085A | 1985-06-24 | 1985-06-24 |
Publications (3)
| Publication Number | Publication Date |
|---|---|
| GB8615260D0 GB8615260D0 (en) | 1986-07-30 |
| GB2176773A true GB2176773A (en) | 1987-01-07 |
| GB2176773B GB2176773B (en) | 1988-10-12 |
Family
ID=25008693
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB8615260A Expired GB2176773B (en) | 1985-06-24 | 1986-06-23 | Abrasion resistant refractory composition |
Country Status (6)
| Country | Link |
|---|---|
| JP (1) | JPS61295277A (en) |
| AU (1) | AU584213B2 (en) |
| BR (1) | BR8602887A (en) |
| CA (1) | CA1247151A (en) |
| DE (1) | DE3621021A1 (en) |
| GB (1) | GB2176773B (en) |
Cited By (10)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR2578536A1 (en) * | 1985-03-06 | 1986-09-12 | Didier Werke Ag | Dry mixt. for alumina-rich fire-concrete |
| FR2622882A1 (en) * | 1987-11-05 | 1989-05-12 | Corhart Refractories Co | REFRACTORY MOLDING COMPOSITION BASED ON HIGH-STRENGTH, ABRASION-RESISTANT, HIGH-TEMPERATURE FOUNDED OXIDES |
| EP0356086A1 (en) * | 1988-08-12 | 1990-02-28 | Btg International Limited | Cement compositions |
| EP0609868A2 (en) * | 1993-02-03 | 1994-08-10 | Asahi Glass Company Ltd. | Monolithic refractory powder mixture |
| EP0690258A1 (en) * | 1994-07-01 | 1996-01-03 | AMSTED Industries Incorporated | Calcium alumina cement lined pipe |
| WO2005017212A1 (en) * | 2003-08-14 | 2005-02-24 | Chosun Refractories Co., Ltd. | Refractory composition for constructing structure in fluidized bed reduction furnace for reduction of iron ore |
| WO2005019482A1 (en) * | 2003-08-26 | 2005-03-03 | Chosun Refractories Co., Ltd. | Refractory composition for constructing dome portion of fluidized bed reduction furnace for reduction of iron ore |
| ES2242538A1 (en) * | 2004-04-16 | 2005-11-01 | Refractarios Alfran S.A. | Refractory composition for projection at high speeds and altitudes up to 120 meters, consists of refractory aggregates, aluminous cement, and additives in variable proportions |
| WO2008060161A1 (en) * | 2006-11-13 | 2008-05-22 | Elkem As | Refractory compositions |
| WO2022090505A1 (en) * | 2020-11-02 | 2022-05-05 | Saint-Gobain Centre De Recherches Et D'etudes Europeen | Sintered alumina product |
Families Citing this family (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5490658A (en) * | 1995-03-02 | 1996-02-13 | Avery Dennison Corporation | Label hangers for intravenous bottles |
| US20130210605A1 (en) | 2010-03-23 | 2013-08-15 | Stellar Materials Incorporated | Refractory composition and process for forming article therefrom |
Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB918884A (en) * | 1960-03-31 | 1963-02-20 | Harbison Walker Refractories | A refractory castable |
Family Cites Families (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS54113617A (en) * | 1978-02-24 | 1979-09-05 | Harima Refractories Co Ltd | Nonshaped refractory having high strength and high fire resistance |
| JPS5692178A (en) * | 1979-12-27 | 1981-07-25 | Toshiba Ceramics Co | Castable refractories |
| JPS5811388B2 (en) * | 1980-01-16 | 1983-03-02 | 大阪窯業耐火煉瓦株式会社 | Amorphous fireproof composition for pouring |
| JPS5935067A (en) * | 1982-08-17 | 1984-02-25 | アジア耐火株式会社 | Castable refractories |
-
1986
- 1986-06-12 CA CA000511422A patent/CA1247151A/en not_active Expired
- 1986-06-17 AU AU58899/86A patent/AU584213B2/en not_active Ceased
- 1986-06-20 DE DE19863621021 patent/DE3621021A1/en not_active Withdrawn
- 1986-06-23 GB GB8615260A patent/GB2176773B/en not_active Expired
- 1986-06-23 BR BR8602887A patent/BR8602887A/en unknown
- 1986-06-24 JP JP61148029A patent/JPS61295277A/en active Granted
Patent Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB918884A (en) * | 1960-03-31 | 1963-02-20 | Harbison Walker Refractories | A refractory castable |
Cited By (16)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR2578536A1 (en) * | 1985-03-06 | 1986-09-12 | Didier Werke Ag | Dry mixt. for alumina-rich fire-concrete |
| FR2622882A1 (en) * | 1987-11-05 | 1989-05-12 | Corhart Refractories Co | REFRACTORY MOLDING COMPOSITION BASED ON HIGH-STRENGTH, ABRASION-RESISTANT, HIGH-TEMPERATURE FOUNDED OXIDES |
| EP0356086A1 (en) * | 1988-08-12 | 1990-02-28 | Btg International Limited | Cement compositions |
| EP0609868A2 (en) * | 1993-02-03 | 1994-08-10 | Asahi Glass Company Ltd. | Monolithic refractory powder mixture |
| EP0609868A3 (en) * | 1993-02-03 | 1995-02-15 | Asahi Glass Co Ltd | Monolithic refractory powder mixture. |
| US5512523A (en) * | 1993-02-03 | 1996-04-30 | Asahi Glass Company Ltd. | Monolithic refractory powder mixture |
| EP0690258A1 (en) * | 1994-07-01 | 1996-01-03 | AMSTED Industries Incorporated | Calcium alumina cement lined pipe |
| TR28772A (en) * | 1994-07-01 | 1997-02-20 | Amsted Ind Inc | Calcium alumina glue lined pipe. |
| WO2005017212A1 (en) * | 2003-08-14 | 2005-02-24 | Chosun Refractories Co., Ltd. | Refractory composition for constructing structure in fluidized bed reduction furnace for reduction of iron ore |
| CN1836053B (en) * | 2003-08-14 | 2012-07-04 | 朝鲜耐火株式会社 | Refractory composition for constructing structure in fluidized bed reduction furnace for reduction of iron ore |
| WO2005019482A1 (en) * | 2003-08-26 | 2005-03-03 | Chosun Refractories Co., Ltd. | Refractory composition for constructing dome portion of fluidized bed reduction furnace for reduction of iron ore |
| CN101759437A (en) * | 2003-08-26 | 2010-06-30 | 朝鲜耐火株式会社 | Refractory composition for constructing dome portion of fluidized bed reduction furnace for reduction of iron ore |
| CN101759437B (en) * | 2003-08-26 | 2013-11-27 | 朝鲜耐火株式会社 | Refractory composition for constructing dome portion of fluidized bed reduction furnace for reduction of iron ore |
| ES2242538A1 (en) * | 2004-04-16 | 2005-11-01 | Refractarios Alfran S.A. | Refractory composition for projection at high speeds and altitudes up to 120 meters, consists of refractory aggregates, aluminous cement, and additives in variable proportions |
| WO2008060161A1 (en) * | 2006-11-13 | 2008-05-22 | Elkem As | Refractory compositions |
| WO2022090505A1 (en) * | 2020-11-02 | 2022-05-05 | Saint-Gobain Centre De Recherches Et D'etudes Europeen | Sintered alumina product |
Also Published As
| Publication number | Publication date |
|---|---|
| AU5889986A (en) | 1987-01-08 |
| JPH0317790B2 (en) | 1991-03-08 |
| AU584213B2 (en) | 1989-05-18 |
| GB8615260D0 (en) | 1986-07-30 |
| CA1247151A (en) | 1988-12-20 |
| GB2176773B (en) | 1988-10-12 |
| DE3621021A1 (en) | 1987-01-02 |
| JPS61295277A (en) | 1986-12-26 |
| BR8602887A (en) | 1987-02-17 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| PCNP | Patent ceased through non-payment of renewal fee |
Effective date: 19980623 |