JP2009522204A - 高温環境での使用のための熱的に安定なセラミック媒体 - Google Patents
高温環境での使用のための熱的に安定なセラミック媒体 Download PDFInfo
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Abstract
Description
本発明の媒体の熱安定性を具体的に示すために、ディスク状の媒体の幾つかのサンプルを調製し、そして以下のように評価した。原料の化学的および物理的パラメーターを、下記の1Aおよび1Bに示す。第1に、表1Aに示す化学分析、及び表1Bに示す粒径分布を有する66部の重焼酸化マグネシウムとともに、同一の化学分析を有するが異なる粒径分布(表1Bを参照)を有する10部の酸化マグネシウム、および表1Aに化学分析を示し、表1Bに示すような粒径分布を有する、第1の市販されているクレイと、第2の市販されているクレイのそれぞれ12部の原料を秤量することによって、混合物を調製した。粉末が均質に混合されるまで、これらの乾燥粉末を高強度の混合機内で乾燥混合した。幾つかの9グラム量のこの混合物を次に、6,900N/m2の圧力で、2.54cm直径のスチールダイで、それぞれプレスした。ディスク状サンプルを次に、1225℃で3時間焼成した。サンプルを次に冷まし、そして秤量スケール、および体積を測定するためにMicromeritics GeoPyc(タイプ1360)からの乾燥媒体ピクノメーターを使用して密度を決定した。ディスクの体積は、本明細書中では、ディスクの第1の体積と定義される。1225℃まで焼成し、そして次に室温まで冷ました後のサンプルの平均密度は、2.265g/ccであった。同じサンプルを1375℃で3時間再加熱し、そして次に22℃まで冷まし、質量および体積を測定し、そして平均密度は、2.29g/ccであった。1375℃まで加熱し、そして次に冷ました後のディスクの体積は、本明細書中ではディスクの第2の体積と定義される。サンプルの質量は変化しなかったので、第2の体積:第1の体積の比率は、0.99:1であった。
押し出し加工によって所望の形に媒体を形成するための、適切な一貫性を有する混合物を作るために、混合物の16wt%を占める水を乾燥成分に加えた以外は、例1中の調合を使用して追加の例を行った。プレスまたはスリップキャスト等の他の成形プロセスの使用もまた可能である。媒体の特有の形を、図3に示された媒体と比較した。媒体の寸法は、長さ42mm、幅28mm、厚さ12mmおよび壁の厚さ4.5mmであった。押し出されたサンプルを1235℃で焼成し、室温まで冷まし、そして密度を2.23g/ccと決定した。媒体の第1の体積は6.50ccであった。媒体の気孔率は32%であった。幾つかのサンプルを1316℃に加熱し、媒体の上に位置する同一の範囲に、5時間、33.0kg荷重をかけた耐熱性匣鉢内に配置した。媒体を冷ました後の媒体の検査は、媒体が変形もしていないし、また共に溶融していないことを明らかにした。媒体の密度は2.28g/ccであり、そして第2の体積は6.36ccであった。第2の体積:第1の体積の比率は0.98:1であった。
例2中に記載された約1320kgの媒体を製造し、そして1215℃の最大焼成温度を有する窯中で焼結した。媒体をX線回折で特徴付け、そして主相はMgOであった。存在した副相は、フォルステライト、スピネルおよびカルシウムマグネシウムシリケートを含んでいた。1400℃で10時間、または1510℃で10時間、または1316℃で数日間再加熱した群に、媒体を分けた。冷ました後で媒体を調べると、媒体は、再加熱の間に変形せず、また共に溶融しなかったことを明らかにした。媒体は物理的に異なっており、そして道具または過度の手の力の使用なしで互いに容易に分離できた。
例4および例5は、酸化マグネシウム系原料、および既発行文献から得られた以下の調合を使用して作製された従来のディスク状の熱的不安定媒体を示すデータを提供することによって、請求項の発明の独自の熱安定性を具体的に示す比較例である。ディスク状サンプルを例1に記載された技術を使用して作製した。X線蛍光による媒体の分析は、以下の組成を明らかにした。
上記記載は、好ましい態様のみの記載と考える。本発明の改変は、当業者および本発明をしもしくは使用するものに起こるであろう。したがって、図および上記に示された態様は、単に具体的に説明する目的だけであり、そして特許法の原理によって解釈される以下の請求項によって規定される本発明の範囲を制限することを目的としないことが理解される。
Claims (42)
- (a)MgOが媒体の48〜78wt%である、MgOと、
(b)SiO2が該媒体の5〜30wt%である、SiO2と、
(c)Al2O3が該媒体の5〜30wt%である、Al2O3と、
含んで成り、
(d)該媒体の見掛け体積に基づいて、該媒体が24%〜38%の多孔質であり、そしてX線回折分析により決定される、該媒体の主相がMgOである、
セラミック媒体。 - 該媒体が、該媒体を低くても1200℃へ加熱した後であるが、該媒体を1250℃より上へ加熱する前の、22℃での該媒体の体積に相当する第1の体積、該媒体を低くても1300℃、しかし1500℃未満に加熱した後の、22℃での該媒体の体積に相当する第2の体積を有し、該第2の体積:該第1の体積の比率が、0.9:1〜1:1である、請求項1のセラミック媒体。
- 該第2の体積:該第1の体積の比率が、0.95:1〜1:1である、請求項2のセラミック媒体。
- 該第2の体積:該第1の体積の比率が、0.98:1〜1:1である、請求項2のセラミック媒体。
- 該第1の体積が、該媒体を低くても1210℃に加熱した後であるが、該媒体を1240℃より上に加熱する前の、22℃での該媒体の体積に相当する、請求項2のセラミック媒体。
- 該第2の体積が、該媒体を低くても1300℃、しかし1500℃未満に少なくとも4時間加熱した後の、22℃での該媒体の体積に相当する、請求項5のセラミック媒体。
- 該第1の体積が、該媒体を低くても1200℃、しかし1250℃未満に少なくとも2時間加熱した後の、22℃での該媒体の体積に相当する、請求項2のセラミック媒体。
- 該第2の体積が、低くても1400℃、しかし1500℃未満に少なくとも4時間加熱した後の、22℃での該媒体の体積に相当する、請求項6のセラミック媒体。
- 該媒体が、28%〜34%多孔質である、請求項1のセラミック媒体。
- 該媒体が、フォルステライト、スピネルおよびカルシウム−マグネシウム−シリケートからなる群から選択される少なくとも1種の副相を含む、請求項1のセラミック媒体。
- (a)酸化マグネシウム、ボールクレイ、ベントナイトおよび長石を含む原料の混合物を用意すること、
該酸化マグネシウムは微粒子形態であり、そして少なくとも45wt%の該粒子は、
30〜250μmである;
(b)複数の3次元媒体に該混合物を形成すること;および、
(c)1200℃超、且つ1250℃未満の焼成温度に該媒体を加熱すること、
該焼結した媒体は、該媒体の見掛け体積に基づいて、24%超且つ38%未満の気孔
率を有し、そしてX線回折分析により決定される該媒体の主相はMgOである;
を含んで成るセラミック媒体の製造方法。 - 少なくとも30wt%の該酸化マグネシウム粒子が、30μmより小さい、請求項11の方法。
- 少なくとも25wt%の該酸化マグネシウム粒子が、250μmより大きい、請求項11の方法。
- 該気孔率が、該媒体の見掛け体積に基づいて、26%超且つ36%未満である、請求項11の方法。
- 該ボールクレイが、25wt%超且つ35wt%未満のAl2O3含有量を有する、請求項11の方法。
- 該ボールクレイが、2wt%未満のMgO含有量を有する、請求項15の方法。
- 該ボールクレイが、約0.4μmのメジアン粒径を有する、請求項16の方法。
- 該ベントナイトが、4wt%未満のMgO含有量を有する、請求項11の方法。
- 該長石が、約15μmの粒径を有する、請求項11の方法。
- 媒体を低くても1200℃に加熱した後であるが、該媒体を1250℃より上に加熱する前の、22℃での該媒体の見掛け体積に相当する第1の体積、および該媒体を低くても1300℃、しかし1500℃より低い温度に加熱した後の、22℃での該媒体の見掛け体積に相当する第2の体積を有し、第2の体積:第1の体積の比率が0.9:1〜1:1である、セラミック媒体。
- 該第2の体積:該第1の体積の比率が0.95:1〜1:1、請求項20のセラミック媒体。
- 該第2の体積:該第1の体積の比率が、0.98:1〜1:1、請求項21のセラミック媒体。
- 該第1の体積が、該媒体を低くても1210℃に加熱した後であるが、該媒体1240℃より上に加熱する前の、22℃での該媒体の体積に相当する、請求項20のセラミック媒体。
- 該第1の体積が、該媒体を低くても1200℃、しかし1250℃未満に、少なくとも2時間加熱した後の、該媒体の体積に相当する、請求項20のセラミック媒体。
- 該第2の体積が、該媒体を低くても1300℃、しかし1500℃未満に、少なくとも4時間加熱した後の、22℃での該媒体の体積に相当する、請求項20のセラミック媒体。
- 該第2の体積が、低くても1400℃、しかし1500℃未満に少なくとも4時間加熱した後の該媒体の体積に相当する、請求項25のセラミック媒体。
- 媒体の焼結温度未満である第1の温度から、該媒体の焼結温度より少なくとも50℃高い第2の温度へ、そして次に該第1の温度に戻る該装置内における熱サイクルの後で、該媒体が物理的に異なっており、そして容易に相互から分離できる、焼結温度で生成された複数のセラミック媒体を含む、化学処理装置。
- 該媒体の焼結温度が、1200℃超且つ1250℃未満である、請求項27の化学処理装置。
- 該第2の温度が、低くても1300℃である、請求項27の化学処理装置。
- 該第2の温度が、低くても1400℃である、請求項27の化学処理装置。
- 該媒体の焼結温度と、該第2の温度との差が少なくとも75℃である、請求項27の化学処理装置。
- 該媒体の焼結温度と、該第2の温度との差が、少なくとも100℃である、請求項27の化学処理装置。
- 該媒体の焼結温度と、該第2の温度との差が、少なくとも150℃である、請求項27の化学処理装置。
- 該媒体の焼結温度と、該第2の温度との差が、少なくとも200℃である、請求項27の化学処理装置。
- 該媒体の焼結温度と、該第2の温度との差が、少なくとも250℃である、請求項27の化学処理装置。
- 該装置が、無炎熱酸化器である、請求項27の化学処理装置。
- 該装置が、再生熱酸化器である、請求項27の化学処理装置。
- 該媒体が、48〜78wt%のMgOを含む、請求項27の化学処理装置。
- 該媒体がSiO2を含み、該SiO2が該媒体の5〜30wt%である、請求項38の化学処理装置。
- 該媒体がAl2O3を含み、該Al2O3が該媒体の5〜30wt%である、請求項39の化学処理装置。
- 該媒体の気孔率が、該媒体の見掛け体積に基づいて24%〜38%である、請求項40の化学処理装置。
- X線回折分析により決定される該媒体の主相が、MgOである、請求項41の化学処理装置。
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US20100212359A1 (en) * | 2009-02-23 | 2010-08-26 | Hilary Tony Godard | Spinel isopipe for fusion forming alkali containing glass sheets |
US9683474B2 (en) | 2013-08-30 | 2017-06-20 | Dürr Systems Inc. | Block channel geometries and arrangements of thermal oxidizers |
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KR20080083702A (ko) | 2008-09-18 |
TW200732268A (en) | 2007-09-01 |
EP1993974A2 (en) | 2008-11-26 |
US20080187470A1 (en) | 2008-08-07 |
KR100945665B1 (ko) | 2010-03-09 |
US20070155612A1 (en) | 2007-07-05 |
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