JP2003207276A - High temperature furnace refractory mending material and mending method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a high temperature furnace refractory mending material and a mending method, used at a time of mending surface deterioration due to thermal history and abrasion of high temperature furnace refractory represented by various industrial furnaces such as a coke oven, a ceramic furnace, a carbon furnace and a combustion furnace, fracture parts due to falling of joints and bricks through holes, and the like, having high adhesiveness, and exhibiting a mending effect for a long period. <P>SOLUTION: This high temperature furnace refractory mending material is obtained by blending (b) 3-25 pts.wt. of glass powder, namely frit powder having a melting point of 500-900°C and composed of 30-60 wt.% of SiO<SB>2</SB>, 5-20 wt.% of Al<SB>2</SB>O<SB>3</SB>, 15-40 wt.% of B<SB>2</SB>O<SB>3</SB>, 10-20 wt.% of Na<SB>2</SB>O, 0-10 wt.% of CaO, and 0-5 wt.% of K<SB>2</SB>O; (c) 0-3 pts.wt. of Ni compound powder, and (d) 10-30 pts.wt. of aqueous solution containing 0-12 wt.% of organic binder and 0-10 wt.% of condensation and hardening accelerator, with (a) 100 pts.wt. of mortar. Water is added to the high temperature furnace refractory mending material when needed, so as to perform cooled and hot mending. <P>COPYRIGHT: (C)2003,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a thermal history of a high temperature furnace refractory typified by various industrial furnaces such as a coke oven, a kiln, a carbon furnace, an incinerator, and surface deterioration due to wear, joints,
The present invention relates to a high-temperature furnace refractory repair material and a repair method, which are used for repairing defective parts due to falling of bricks and the like, through holes, etc., have high adhesiveness, and exhibit a repair effect for a long period of time.

[0002]

2. Description of the Related Art Bricks, joints, and irregular refractory materials used in furnaces, furnace lids, furnace doors, etc. of high-temperature furnaces such as coke ovens, kiln ovens, carbon furnaces, incinerators, and other industrial furnaces. , Other refractories are exposed to high temperatures all the time, so they are severely deteriorated. In particular, the refractory bricks around the cast iron frame near the kiln port in the coke oven carbonization chamber are liable to peel or crack due to mechanical (physical) factors such as impact caused by opening / closing of the furnace lid, and also the degree of surface deterioration. It will be big. This phenomenon impairs the airtightness in the furnace and causes gas leakage, which is a serious problem in coke quality and operation particularly in the coke oven carbonization chamber. In order to solve such a problem, there is a method of blowing powder refractory into joint breaks of bricks, defective parts of bricks, etc. as repair of an industrial furnace. For example, Japanese Patent Publication No. 55-46998 discloses mainly mortar. As an ingredient,
A composition in which a bituminous product and a liquid oil are mixed is described therein, and Japanese Patent Publication No. 56-5713 discloses a basic refractory aggregate (for example, magnesia clinker) as a main component, and a lithium compound, clay and silica. A composition in which sodium acid salt is added and blended is described, and Japanese Patent Publication No. 56-15763.
The publication describes a repairing method in which a powdery refractory material containing magnesia clinker as a main component is hot sprayed with a dry spraying device. Furthermore, the inventors of the present invention disclosed in Japanese Patent Laid-Open No. 11-23
Japanese Patent No. 6276 and Japanese Patent Application Laid-Open No. 2001-48661 propose a composition in which an aqueous solution containing an alkali silicate salt, an alkaline borate salt, an alkaline phosphate salt, or the like is added to and mixed with a mortar. As can be seen from these, as the repair material, those used by the dry method and those used by the wet method have been proposed. In both methods, the repair material supplied from the pressure tank is attached to the furnace wall with a gun or nozzle. Use and spray.
However, in reality, inexpensive mortar or repair material mainly composed of mortar is most widely used for repairing the refractory material of the high temperature furnace.

[0003]

However, since the conventional repair material basically has low adhesiveness to various refractory materials such as bricks, it easily peels or cracks due to the various factors mentioned above to cause fire resistance. Since it fell off the surface of the object, the effect of the repair disappeared in a short period of time, and as a result, repair work had to be performed frequently. In addition, especially when the repair material to be sprayed contains a large amount of water, or when repairing a large defect part that is missing deep inside the refractory, a large amount of steam is generated when the repair material solidifies at high temperature. Under internal pressure, this internal pressure makes it easier for the repair material to separate from the furnace wall, or to cause cavitation due to foaming accompanying evaporation of the low-melting point substance, which causes cracks,
The repair life was short. For example, in the case of mortar spraying, which is widely used in general, it is possible to obtain a suitable particle size distribution containing particles of 0.05 mm to several mm and the main components are SiO ₂ and Al ₂ O ₃ and therefore, it is possible to use the foaming as described above. Although there are few cavities, the repair life is 1 because the adhesive strength with refractories is extremely weak.
It was about a week. Also, for example, the repair of the dropout defect part of the large refractory found in the coke oven door etc. is usually carried out by cold repair at normal temperature, but when repaired with the repair material containing mortar as the main component, it is dried. In addition to being slow, the adhesive strength to the refractory at room temperature is weak, so there are many deficiencies such as peeling of the adhesion part when attaching the repaired door to the coke oven, etc. It has a drawback that repair work is complicated, such as requiring many anchors.Furthermore, when performing hot repair of these mortar repair materials in a high-temperature furnace, the relatively thin part of the refractory surface It is effective for repair, but when the thickness of the part of the refractory is large (several tens of cm), the repair material was not sufficiently adhered, and it was often seen that it fell off during repair work. Thus, at present, with mortar as the main repair material, both cold and hot repair work can repair a wide range from the refractory surface to the inside of the refractory, and show a long-term repair effect. I couldn't find anything.

[0004]

DISCLOSURE OF THE INVENTION The present invention uses a composition obtained by combining a mortar with a specific composition in a relatively small amount so that the surface of a high temperature furnace refractory constituting various industrial furnaces can be repaired. It is possible to repair a wide range of defects, from deep to deeply missing, and has a high adhesive strength and compressive strength in both cold and hot repair work, and does not cause foaming or cracks, resulting in a repair life. It is intended to provide a repair material having excellent properties that are several times to several tens of times higher than the case where only mortar is used, and a repair method using the repair material.

The mortar type repair material used for repairing the refractory material of the high temperature furnace of the present invention is (f) frit powder 3 having a melting point of 500 to 900 ° C. with respect to 100 parts by weight of mortar.
˜25 parts by weight, (c) Ni compound powder 0 to 3 parts by weight, (d) organic binder 0 to 12% by weight, and coagulation hardening accelerator 0 to 10
It is characterized by being mixed with 10 to 30 parts by weight of an aqueous solution containing wt%. The high temperature furnace refractory repair method of the present invention is characterized by performing cold or hot repair work by adding water to the repair material, if necessary.

[0006]

BEST MODE FOR CARRYING OUT THE INVENTION In the repair material and repair method of the present invention,
Each of the components (a) to (d) used will be described in detail.
First, (a) mortar used in the present invention is not particularly limited.
Generally, it is not₂And Al₂O₃The main component
As Fe₂O₃, CaO, MgO, Na₂O, K ₂O etc.
What is appropriately mixed may be used.

The melting point (b) used in the present invention is 500 to 90.
The frit powder having a temperature of 0 ° C. is composed of 30 to 60 wt% of SiO ₂ , A
_{l 2 O 3 5~20wt%, B} 2 O 3 15~40wt%, Na 2 O1
It is a glassy powder composed of 0 to 20 wt%, CaO 0 to 10 wt% and K ₂ O 0 to ₅ wt%. The manufacturing method of frit powder is
The constituent components are melted (vitrified) at a high temperature and then pulverized at room temperature, and the foaming phenomenon associated with the evaporation of the low-melting point substance can be made extremely small as compared with the case where the components are simply mixed. The role of this frit powder in the repair material is to enhance the adhesive strength and compressive strength at high temperatures.

Examples of the (c) Ni compound powder used in the present invention include Ni (OH) ₂ , NiO, Ni ₂ O ₃ and NiCO ₃ .
One or more of these can be appropriately used. This N
The role of the i compound powder in the repair material is to improve the adhesion between the refractory in the furnace and the repair material, and to improve the adhesive strength and bending strength.

(D) Organic binder used in the present invention
An aqueous solution containing 12 wt% and 0 to 10 wt% setting accelerator contains 78 to 100 wt% water. As the organic binder in this aqueous solution, there are polyvinyl alcohol, gum arabic, carboxymethyl cellulose, dextrin, methyl cellulose and the like, and one or more of them can be appropriately used. The role of this organic binder component in the repair material is to increase the adhesive strength at room temperature when performing cold repair work. Further, as the setting and hardening accelerator in this aqueous solution, there are sodium aluminate, sodium carbonate, calcium chloride, sodium hexametaphosphate, sodium metaphosphate and the like, and one or more of them can be appropriately used. The role of the setting hardening accelerator in the repair material is to appropriately accelerate the drying property at room temperature, that is, the setting hardening property in the case of performing cold repairing, and to increase the compressive strength at room temperature. However, excessive acceleration of setting and hardening hinders the organic binder component from reaching the adhesive surface,
In order to reduce the adhesive strength at room temperature, the amount is made as small as 1 to 10 wt%, preferably 1 to 5 wt%.

In the repair method of the present invention, cold or hot repair work is carried out by adding water to the repair material composed of the components (a) to (d) as needed. For example, taking the case where the high temperature furnace refractory is a coke oven carbonization chamber as an example, cold repair work may be performed by blowing or pouring the door castable defect portion. Examples of hot repairing work include repairing high-pressure spray from a kiln mouth of a carbonization chamber to a defect portion caused by dropping of a refractory such as a high-temperature wall surface in the carbonization chamber by using a gun or a nozzle. In the case of hot repair, organic binder and setting hardening accelerator can be excluded from the formulation. Describing based on the conceptual diagram shown in FIG. 1, a delivery port connected to the repair material container 3 is provided at the tip of the discharge flow path 2 connected to the compressor 1, and the repair material premixed and necessary The repair material 4 prepared by adding water accordingly may be sprayed using a spray device having a nozzle 5 at the tip, and the discharge pressure is 5 to 8 kg / cm ² , and the spray amount sprayed on the furnace wall. Depending on the extent of brick failure, spraying is performed so that the coating thickness of the repair material is smooth as a whole. The amount of water added is (d) the composition concentration of the organic binder and the coagulation hardening accelerator, (a) the mortar,
It is appropriately determined by the proportions of (b) frit powder and (c) Ni compound, and the construction method and location.

[0011]

[Example] Example 1 A test piece frame having a size of 40 x 40 x 160 mm was provided with 4 pieces.
Insert refractory bricks cut and molded to 0x40x80mm,
The repair materials of the formulation examples 1 to 7 and the comparative example shown in Table 1 were kneaded and prepared, and poured into the remaining half of the test piece frame,
Create two each of the same species. After drying at room temperature (about 20 ° C.) for 3 days (72 hours), it was taken out from the test piece frame. One of two pieces of the same kind was used as a test piece which was dried at room temperature, and the other one was further baked for 3 hours in an electric furnace at 800 ° C. to obtain a test piece for baking. Then, the performance of the repair material was judged from the test results of adhesive strength and bending strength. Here, the adhesive strength is indicated by a measured value of the bending strength at the interface between the repair material and the refractory brick in the test piece. The porosity of the fired test body was measured and used as a measure of gas permeability. The results are shown in Table 2.

[0012]

[Table 1]

[Table 2]

Example 2 Repair materials of Formulation Examples 1 to 8 and Comparative Example shown in Table 1 were kneaded and prepared, repaired in an operating coke oven carbonization chamber, and an actual machine test was conducted. The outline specifications of the actual coke oven are: Number of kilns: 86 kilns, 2. Carbonization chamber dimensions / height: 6.5 m / width: 420 mm / length:
15.9m, 3. Time required for one cycle: 23 hours, 4. Coke extrusion time: 5 minutes, 5. Carbonization chamber furnace wall temperature, central part: 1100 to 1200 ° C
Kiln mouth part: It is 900-1100 degreeC. As the repair material, coke was extruded and then sprayed by using the spray device shown in FIG. The temperature of the furnace wall near the hot kiln is 500
~ 800 ℃, repair range is 100 ~ 1 from the kiln
Up to about 50 cm. Also, the thickness of the repair material applied is not constant because it sprays thickly on the missing parts, but it is approximately 10 to 60 mm, and the amount of repair material used is 2 to
It was 10 kg / m ² . The formed repair surface had high smoothness. The inspection items are the adhesiveness (peeling resistance) of the repair material to the brick, and gas leakage. The number of days until the repair material comes off after spray application and the number of days until gas leakage are visually observed. did. The results are shown in Table 3.

[0014]

[Table 3]

[0015]

As described above, the high-temperature furnace refractory repair material of the present invention has higher adhesiveness and adhesiveness with the refractory brick even at room temperature than the conventional repair materials, and after firing, The refractory repair part in hot working is rich in strength, impact resistance, and durability, and has good insulation against gas leakage. Therefore, the repair by cold working or hot working using the above repair material enables long-term protection of refractories of various industrial high temperature furnaces including the coke oven carbonization chamber.

[Brief description of drawings]

FIG. 1 is a conceptual diagram showing an example of a spray mechanism for spraying a repair material of the present invention.

─────────────────────────────────────────────────── ─── Continuation of front page (51) Int.Cl. ⁷ Identification code FI theme code (reference) C04B 35/66 C04B 35/66 NS F27D 1/16 F27D 1/16 V (72) Inventor Yuji Tsukihara 1-chome, Mizushima-Kawasaki-dori, Kurashiki-shi, Okayama (No house number) Kawasaki Steel Co., Ltd. Mizushima Works (72) Inventor Mitsuo Onozawa 9 Kirihara-machi, Fujisawa-shi, Kanagawa Taiho Engineering Co., Ltd. Central Research Institute (72) Inventor Nakai Shigeru 9 Kirihara Town, Fujisawa City, Kanagawa Prefecture F-Term in Central Research Laboratory, Taiho Industrial Co., Ltd. (reference) 4G033 AA01 AB01 AB02 AB03 AB08 AB21 AB22 AB23 4K051 AA00 AA08 AA09 AB01 AB03 AB05 AB07 AB09 BE00 BE01 BE03 LJ01

Claims (5)

[Claims] 1. A frit powder 3 to 2 having a melting point of 500 to 900 ° C. (b) with respect to 100 parts by weight of (a) mortar.
5 parts by weight, (c) 0 to 3 parts by weight of Ni compound powder, (d) 0 to 12% by weight of organic binder, and setting hardening accelerator 0
A high temperature furnace refractory repair material, characterized by comprising 10 to 30 parts by weight of an aqueous solution containing 10 wt%. 2. The frit powder is SiO ₂ 30-60 wt.
%, Al ₂ O _{3 5 to} 20 wt%, B ₂ O ₃ 15 to 40 wt%, Na
₂ O 10-20 wt%, CaO 0-10 wt%, K ₂ O0-5w
The high temperature furnace refractory repair material according to claim 1, which is a glassy powder composed of t%. 3. The high temperature furnace refractory repair material according to claim 1, wherein the organic binder is one or more of polyvinyl alcohol, gum arabic, carboxymethyl cellulose, dextrin, and methyl cellulose. 4. The setting hardening accelerator is one or more of sodium aluminate, sodium carbonate, calcium chloride, sodium hexametaphosphate, and sodium metaphosphate, and any one of claims 1 to 3 is characterized in that High temperature furnace refractory repair material. 5. A frit powder 3 to 2 having a melting point of 500 to 900 ° C. (b) with respect to 100 parts by weight of (a) mortar.
5 parts by weight, (c) 0 to 3 parts by weight of Ni compound powder, (d) 0 to 12% by weight of organic binder, and setting hardening accelerator 0
10 to 30 parts by weight of an aqueous solution containing 10 to 10 wt% is added to a high-temperature furnace refractory repair material, and water is added as necessary to perform cold or hot repair work. Item repair method.