JP2019048761A - 高ジルコニア質電鋳耐火物及びその製造方法 - Google Patents
高ジルコニア質電鋳耐火物及びその製造方法 Download PDFInfo
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- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 title claims abstract description 164
- 239000011819 refractory material Substances 0.000 title claims abstract description 66
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 32
- 239000000203 mixture Substances 0.000 claims abstract description 8
- 239000000126 substance Substances 0.000 claims abstract description 8
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 26
- 229910004298 SiO 2 Inorganic materials 0.000 claims description 20
- KKCBUQHMOMHUOY-UHFFFAOYSA-N Na2O Inorganic materials [O-2].[Na+].[Na+] KKCBUQHMOMHUOY-UHFFFAOYSA-N 0.000 claims description 13
- 239000002994 raw material Substances 0.000 claims description 12
- 239000000377 silicon dioxide Substances 0.000 claims description 12
- 229910052681 coesite Inorganic materials 0.000 claims description 10
- 229910052906 cristobalite Inorganic materials 0.000 claims description 10
- 235000012239 silicon dioxide Nutrition 0.000 claims description 10
- 229910052682 stishovite Inorganic materials 0.000 claims description 10
- 229910052905 tridymite Inorganic materials 0.000 claims description 10
- 229910004742 Na2 O Inorganic materials 0.000 claims description 8
- 229910052799 carbon Inorganic materials 0.000 claims description 7
- 229910018072 Al 2 O 3 Inorganic materials 0.000 claims description 6
- 230000005484 gravity Effects 0.000 claims description 3
- 238000005260 corrosion Methods 0.000 abstract description 18
- 230000007797 corrosion Effects 0.000 abstract description 18
- 239000006060 molten glass Substances 0.000 abstract description 16
- 230000015572 biosynthetic process Effects 0.000 abstract description 9
- 239000011521 glass Substances 0.000 description 41
- 239000011159 matrix material Substances 0.000 description 26
- 239000011734 sodium Substances 0.000 description 22
- 239000000463 material Substances 0.000 description 13
- 229910052845 zircon Inorganic materials 0.000 description 11
- GFQYVLUOOAAOGM-UHFFFAOYSA-N zirconium(iv) silicate Chemical compound [Zr+4].[O-][Si]([O-])([O-])[O-] GFQYVLUOOAAOGM-UHFFFAOYSA-N 0.000 description 11
- 230000000052 comparative effect Effects 0.000 description 10
- 238000002844 melting Methods 0.000 description 10
- 230000008018 melting Effects 0.000 description 10
- 238000005336 cracking Methods 0.000 description 9
- 238000012360 testing method Methods 0.000 description 8
- 239000013078 crystal Substances 0.000 description 6
- 230000000694 effects Effects 0.000 description 6
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 5
- 238000001816 cooling Methods 0.000 description 5
- 229910002804 graphite Inorganic materials 0.000 description 5
- 239000010439 graphite Substances 0.000 description 5
- 230000001629 suppression Effects 0.000 description 5
- 239000012535 impurity Substances 0.000 description 4
- 239000003513 alkali Substances 0.000 description 3
- 238000004040 coloring Methods 0.000 description 3
- 238000010438 heat treatment Methods 0.000 description 3
- 238000004445 quantitative analysis Methods 0.000 description 3
- 238000004017 vitrification Methods 0.000 description 3
- CDBYLPFSWZWCQE-UHFFFAOYSA-L Sodium Carbonate Chemical compound [Na+].[Na+].[O-]C([O-])=O CDBYLPFSWZWCQE-UHFFFAOYSA-L 0.000 description 2
- 229910010413 TiO 2 Inorganic materials 0.000 description 2
- 238000004458 analytical method Methods 0.000 description 2
- 238000005266 casting Methods 0.000 description 2
- 238000010549 co-Evaporation Methods 0.000 description 2
- 238000011109 contamination Methods 0.000 description 2
- 238000005323 electroforming Methods 0.000 description 2
- 238000000034 method Methods 0.000 description 2
- 230000000704 physical effect Effects 0.000 description 2
- BWHMMNNQKKPAPP-UHFFFAOYSA-L potassium carbonate Chemical compound [K+].[K+].[O-]C([O-])=O BWHMMNNQKKPAPP-UHFFFAOYSA-L 0.000 description 2
- 239000004576 sand Substances 0.000 description 2
- 238000005382 thermal cycling Methods 0.000 description 2
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- 229910000323 aluminium silicate Inorganic materials 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 description 1
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 description 1
- 238000005485 electric heating Methods 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 238000001704 evaporation Methods 0.000 description 1
- 230000008020 evaporation Effects 0.000 description 1
- 238000005187 foaming Methods 0.000 description 1
- 230000006698 induction Effects 0.000 description 1
- 239000004615 ingredient Substances 0.000 description 1
- 230000000977 initiatory effect Effects 0.000 description 1
- 238000011835 investigation Methods 0.000 description 1
- 230000005923 long-lasting effect Effects 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 229910052863 mullite Inorganic materials 0.000 description 1
- 238000001637 plasma atomic emission spectroscopy Methods 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 229910000027 potassium carbonate Inorganic materials 0.000 description 1
- 230000002265 prevention Effects 0.000 description 1
- 238000011002 quantification Methods 0.000 description 1
- 229910000029 sodium carbonate Inorganic materials 0.000 description 1
- 230000008646 thermal stress Effects 0.000 description 1
- 238000004876 x-ray fluorescence Methods 0.000 description 1
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- 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
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- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
- C03B5/00—Melting in furnaces; Furnaces so far as specially adapted for glass manufacture
- C03B5/16—Special features of the melting process; Auxiliary means specially adapted for glass-melting furnaces
- C03B5/42—Details of construction of furnace walls, e.g. to prevent corrosion; Use of materials for furnace walls
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- C04B35/48—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 zirconium or hafnium oxides, zirconates, zircon or hafnates
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- C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
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- C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
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Abstract
Description
0.15質量%≦CK2O/2+CNa2O≦0.6質量% …(1)
(式中、CK2OはK2Oの含有量、CNa2OはNa2Oの含有量、であり、これら含有量はいずれも耐火物中における質量%で表す。)の関係を満たすことを特徴とする。
0.15質量%≦CK2O/2+CNa2O≦0.6質量% …(1)
(式中、CK2OはK2Oの含有量、CNa2OはNa2Oの含有量、であり、これら含有量はいずれも耐火物中における質量%で表す。)の関係を満たすように配合される。
0.09≦ (CK2O/2+CNa2O)/CSiO2 ≦0.4 …(2)
(式中、CNa2OはNa2Oの含有量、CK2OはK2Oの含有量、CSiO2はSiO2の含有量であり、これら含有量はいずれも耐火物中における質量%で表す。)の関係を満たすことが好ましい。
0.11≦ (CK2O/1.5+CNa2O)/CSiO2 ≦0.5 …(3)
(式中、CNa2OはNa2Oの含有量、CK2OはK2Oの含有量、CSiO2はSiO2の含有量であり、これら含有量はいずれも耐火物中における質量%で表す。)の関係を満たすことが好ましい。
そのため、マトリックスガラス中の他の成分の含有量の調整のため、[(CK2O/1.5+CNa2O)/CSiO2]は0.5以下である。
2 ≦ CK2O/CNa2O …(4)
(式中、CK2OはK2Oの含有量、CNa2Oは、であり、これら含有量はいずれも耐火物中における質量%で表す。)の関係を満たすことが好ましい。
残存体積膨張率(%)=(熱サイクル試験後の体積/熱サイクル試験前の体積)−1)×100
鋳塊の外観上の亀裂について次のように評価した。
高ジルコニア質電鋳耐火物の鋳塊から押し湯部分を切除して、厚み200mm×幅400mm×高さ900mm(質量:約400kg)の電鋳耐火物を製造した。この電鋳耐火物の表面に肉眼で確認できる亀裂の全ての長さを測定し、その合計長さを、次の基準で評価した。
優:亀裂合計長さが150mm以下である。
良:亀裂合計長さが150mm超300mm以下である。
可:亀裂合計長さが300mm超600mm以下である。
不可:亀裂合計長さが600mm超である。
製造した電鋳耐火物から厚み50mm×幅50mm×高さ50mmの試料を切り出し、800℃と1250℃の間を40回往復させる加熱・冷却を電気炉中で実施した。この際、室温から800℃の間の加熱は毎時160℃にて行い、ここから、800℃到達後直ちに1250℃への加熱を毎時450℃にて行い、1250℃到達後直ちに800℃までの冷却を毎時450℃にて行って1回の熱サイクルとした。その後、上記と同じ操作で、800℃と1250℃とを往復する熱サイクルを40回繰り返した。最終の熱サイクル後は毎時160℃の速度にて800℃から室温まで冷却した。この試験前及び試験後で試料の寸法を測定し、その寸法変化から残存体積膨張率を求めた。このとき得られた残存体積膨張率を、次の基準により評価した。
良:残存体積膨張率が10%超20%以下である。
可:残存体積膨張率が20%超30%以下である。
不可:残存体積膨張率が30%超である。
上記亀裂と残存膨張率の評価結果に応じて、以下の基準で判定した。
優:亀裂、残存体積膨張率が共に優である。
良:亀裂、残存体積膨張率の一方が良で、もう一方が可及び不可ではない。
可:亀裂、残存体積膨張率の一方が可であり、もう一方が不可ではない。
不可:亀裂、残存体積膨張率のいずれかが不可である。
Claims (7)
- 化学組成として、酸化物基準で、ZrO2を96.7〜98.5質量%、SiO2を0.8〜2.7質量%、Al2O3を0.1〜0.4質量%、Na2Oを0〜0.2質量%、K2Oを0.21〜1質量%、含有し、B2O3を実質的に含有せず、
前記Na2O及び前記K2Oの含有量が、次の式(1)
0.15質量%≦CK2O/2+CNa2O≦0.6質量% …(1)
(式中、CK2OはK2Oの含有量、CNa2OはNa2Oの含有量、であり、これら含有量はいずれも耐火物中における質量%で表す。)の関係を満たすことを特徴とする高ジルコニア質電鋳耐火物。 - 前記Na2O、前記K2O及び前記SiO2の含有量が、次の式(2)
0.09≦(CK2O/2+CNa2O)/CSiO2≦0.4 …(2)
(式中、CK2OはK2Oの含有量、CNa2OはNa2Oの含有量、CSiO2はSiO2の含有量であり、これら含有量はいずれも耐火物中における質量%で表す。)の関係を満たす請求項1に記載の高ジルコニア質電鋳耐火物。 - 前記CNa2Oに対する前記CK2Oの比(CK2O/CNa2O)が2以上である請求項1又は2に記載の高ジルコニア質電鋳耐火物。
- 嵩比重が5.4以上である請求項1乃至3のいずれか1項記載の高ジルコニア質電鋳耐火物。
- 気孔率が1.5%以下である請求項1乃至4のいずれか1項記載の高ジルコニア質電鋳耐火物。
- その質量が200kg以上である請求項1乃至5のいずれか1項記載の高ジルコニア質電鋳耐火物。
- 耐火物原料を高温で溶解し、鋳型中で冷却して、請求項1〜6のいずれか1項に記載の高ジルコニア質電鋳耐火物を製造することを特徴とする高ジルコニア質電鋳耐火物の製造方法。
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TW107126673A TW201912610A (zh) | 2017-09-08 | 2018-08-01 | 高氧化鋯質電鑄耐火物及其製造方法 |
KR1020180104474A KR20190028309A (ko) | 2017-09-08 | 2018-09-03 | 고지르코니아질 전기 주조 내화물 및 그 제조 방법 |
EP18192492.9A EP3453689B1 (en) | 2017-09-08 | 2018-09-04 | High-zirconia electrocast refractory and method for manufacturing the same |
CN201811045414.0A CN109467447B (zh) | 2017-09-08 | 2018-09-07 | 高氧化锆质电铸耐火物及其制造方法 |
US16/124,913 US10815155B2 (en) | 2017-09-08 | 2018-09-07 | High-zirconia electrocast refractory and method for manufacturing the same |
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JPH0848573A (ja) * | 1994-08-10 | 1996-02-20 | Toshiba Monofrax Co Ltd | 高ジルコニア溶融耐火物 |
JP2010260782A (ja) * | 2009-04-06 | 2010-11-18 | Asahi Glass Co Ltd | 高ジルコニア質耐火物及び溶融窯 |
JP2013514254A (ja) * | 2009-12-16 | 2013-04-25 | サン−ゴバン サントル ド レシェルシュ エ デテュド ユーロペアン | 高いジルコニア含有量を有する耐火物 |
WO2012046785A1 (ja) * | 2010-10-06 | 2012-04-12 | 旭硝子株式会社 | 高ジルコニア質電鋳耐火物 |
WO2013151106A1 (ja) * | 2012-04-06 | 2013-10-10 | 旭硝子株式会社 | 高ジルコニア質電鋳耐火物 |
JP2014129199A (ja) * | 2012-12-28 | 2014-07-10 | Agc Ceramics Co Ltd | 高ジルコニア質電鋳耐火物 |
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WO2022114022A1 (ja) | 2020-11-24 | 2022-06-02 | サンゴバン・ティーエム株式会社 | 高ジルコニア電気溶融鋳造耐火物 |
KR20230110446A (ko) | 2020-11-24 | 2023-07-24 | 산고반.티에무 가부시키가이샤 | 고지르코니아 전기 용융 주조 내화물 |
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