JP4603477B2 - Method of spraying irregular refractories and spraying materials used therefor - Google Patents

Description

  The present invention relates to the construction of various metal containers and kilns such as blast furnaces, firewood, kneading cars, converters, ladle, secondary smelting furnaces, tundish, cement rotary kilns, waste melting furnaces, incinerators, and non-ferrous metal containers. The present invention relates to a method for spraying an irregular refractory in a furnace or repair and a spraying material used for the method.

  The method of spraying irregular refractories can be broadly divided into wet construction methods and dry construction methods.

  The wet construction method is a construction method in which construction water is added to a material in advance and kneaded to form a slurry-like spraying material (unshaped refractory), and a quick setting agent or the like is added and sprayed at the tip nozzle portion. On the other hand, the dry construction method is a construction method in which a spray material (irregular refractory) is pneumatically transported in a dry state, and the construction water is injected and sprayed with a nozzle portion at the tip.

  The wet construction method is capable of forming a dense refractory spray construction body having better adhesion than the dry construction method, and has the effect of reducing the amount of dust generated during construction. On the other hand, a kneading device and a slurry pumping device are required for spraying. In addition, the structure of the device is complicated and expensive, and after the spraying operation, the slurry-like amorphous refractory adheres to the kneading device and the material transport pipe. However, there is a drawback that it takes time for the cleaning operation.

  On the other hand, the dry construction method basically only injects construction water into the spray material that is conveyed in air in the dry state at the tip nozzle part, so the spray device is simple and excellent in workability However, since the spray material is sprayed in a state where moisture is not sufficiently mixed, a lot of dust is generated during spraying, and the refractory structure of the sprayed body tends to be uneven. Also, the adhesion rate, adhesive strength and corrosion resistance are inferior. Compared with the wet construction method, there is also a drawback that it is difficult to obtain a dense construction body because the kneading effect is low and the amount of water used is large.

  Usually, in order to inject construction water at the tip nozzle portion, it is common to inject pressurized water from a plurality of through holes provided on the outer peripheral surface of the nozzle toward the center of the nozzle or in front of the nozzle (Patent Document 1). It is considered that the water to be poured should be dispersed and atomized in order to wet the material in the material transport pipe.

For example, in Patent Document 2, water is pumped to a water jet port that is opened in a diametrical direction to a pipe body that communicates with a material hose, and mist-like water is jetted into the pipe body to form a curtain wall. A method is described in which a spraying material (refractory raw material) is pumped from a material hose and mist water and the spraying material are mixed in a tubular body using pumped air. It is also described that when the diameter of the opening end of the water outlet is 0.01 mm to 1 mm and a water pressure of 30 to 50 kg / cm ² is applied, the water becomes mist and forms a curtain wall.

  However, in this method, since water is supplied in the form of a mist at the tip nozzle part, it is actually difficult and sufficient to wet the spray material uniformly to the center against the air flow that pumps the spray material. There is a problem that the kneading effect is difficult to obtain. Further, when the amount of sprayed material is increased, for example, 70 kg / min, it is necessary to add a large amount of water. However, it is difficult to add a large amount of water in the case of atomized water. Furthermore, if it is attempted to increase the amount of water added, it must be sprayed in a large water droplet state, and the kneading state becomes worse.

  In addition, in order to enhance the kneading effect, a method of pouring water from a plurality of locations and a method aiming at the kneading effect in the nozzle by lengthening the nozzle have been proposed in the past, but it can be kneaded with low moisture as expected. In both cases, there is a problem that a person is too heavy to work with a nozzle.

  Therefore, in order to improve the kneading effect of water and the spray material in the spray construction method, water is injected in the transport path of the material transport pipe for transporting the spray material, and the spray materials in the material transport pipe or between the spray materials are sprayed. The construction method aiming at the kneading effect by the collision between the adhesive material and the inner surface of the material conveying pipe has been studied in the past.

  For example, Patent Document 3 discloses a spray construction method in which water is added at two locations, a compressed air pipe for spray material transport and a spray nozzle. In addition, it is described that water is sprayed as pre-kneading in the compressed air for conveying the spray material. By adding water dispersed uniformly in the air in this way, the shortage of kneading can be eliminated and the use of short nozzles can be achieved, and material adhesion in the material transport pipe due to local non-uniformity of water is prevented. It is described that it can. Certainly, this method reduces dust generation compared to adding only water with a spray nozzle alone, and is thought to be effective in preventing material adhesion in the material transport pipe. It is difficult to wet the spray material uniformly and a good kneading effect cannot be obtained. For this reason, compared with the conventional dry construction method, it was not possible to perform precise construction with low moisture.

  Further, Patent Document 4 adds a working water amount and compressed air that can be poured into an amorphous refractory composition conveyed by air through a water ring before the spray nozzle to obtain soft workability, and further includes a spray nozzle section. Discloses a two-stage water injection method in which a flocculant or a shape retention agent is added and sprayed. And in this method, if construction water is added using high-pressure compressed air, it is described that the uniform mixing of the amorphous refractory and water can be performed in a short time due to its powerful stirring action. As a result, problems with conventional dry methods and semi-dry construction methods such as environmental deterioration due to rebound loss and deterioration of construction quality due to moisture increase, complicated spray equipment, troublesome cleaning, It is described that the problems of the conventional wet method such as a large amount of residual agent disposal are solved.

  However, in the method of Patent Document 4, a large amount of high-pressure compressed air is required to add all the water necessary for the construction. When a large amount of high-pressure compressed air is blown from the water ring, the spray material is uniform. Kneading, and may cause pulsation. For this reason, there is a problem that it is difficult to obtain a dense construction body.

  Furthermore, in Patent Document 5, a spray material containing a refractory material aggregate, a refractory powder, a binder, a dispersant, and a quick setting agent is put in an air stream in a powder state and sent into a material transport pipe. A spraying construction method is disclosed in which the entire amount of construction water is injected in the middle, and then airflow (air) is conveyed and sprayed through a spray nozzle. And even after the entire amount of construction water is poured in the middle of the material transport pipe and becomes wet, the amorphous refractory composition does not become viscous to adhere to the material transport pipe, and the conventional wet spraying method and It is said that the same amount of added water and quality of the construction body can be obtained.

  However, when this method was used for testing, simply irrigating the entire construction water in the middle of the material transport pipe did not allow water to become familiar to the powder material, particularly the ultrafine powder material in the spray material, and the kneading state was insufficient. As a result, the rebound loss and dust generation were large and the workability was inferior, and it was found that there was a disadvantage that a stable quality sprayed body could not be obtained.

  For this reason, in order to satisfy workability, the amount of moisture is inevitably increased, and the amount of moisture varies depending on the location, where the portion having too much moisture has a high porosity, and conversely, the portion having too little moisture is not bonded. There is a problem that the sufficient durability is not obtained and the predetermined durability cannot be obtained at any part. In addition, when water is added from a position away from the nozzle hole at the tip, the material starts to aggregate due to dissolution of the quick setting agent, so that the amount of added water increases, and there is a problem that complicated work of cleaning the material transport pipe increases.

  In addition, Patent Document 5 discloses that water is added as a premoist, but this is for the purpose of preventing dust generation. I can't get it.

Therefore, in order to solve the above-mentioned problems, the present inventors, in PCT / JP2005 / 10431, are a construction method in which water is injected from two locations into a spray material transported in a material transport pipe, and the average particle size is measured from the water injector. A spraying method for an irregular refractory was proposed in which atomized water of 100 μm or less was injected together with compressed air. According to this method, by spraying water as atomized water having a plain particle size of 100 μm or less, the spray material can be uniformly moistened with low moisture, so that an effect of obtaining a dense construction body can be obtained. . However, if a large amount of spraying is attempted at a time, for example, at a spraying material supply speed of about 70 kg / min, the amount of compressed air for blowing atomized water becomes too large, resulting in an increase in rebound loss and the like. Moreover, it has been found that there is a problem that it is difficult to obtain a dense construction body.
Japanese Patent Publication No.59-4194 JP 62-129166 A JP-A-63-31562 JP-A-10-316478 JP 2002-220288 A

  An object of the present invention is to provide a spraying method that improves the kneading effect of moisture and spraying material, can obtain a dense construction body with low moisture content, and is excellent in workability, and a spraying material used therefor There is to do.

  The present invention is a method for spraying an irregular refractory material in which construction water is injected from a water injector and sprayed onto a spray material transported in a material transport pipe, and the average particle from the water injector is injected into the material transport pipe. The construction water containing 0.1 to 30% by volume of bubbles having a diameter of 100 μm or less is poured so as to incline at 30 to 70 degrees with respect to the material transport direction and collide almost at the center in the material transport pipe, and the average particle size is 100 μm. It is a spray construction method for an amorphous refractory characterized by generating the following atomized water.

  In the present invention, the construction water containing air as air bubbles having an average particle size of 100 μm or less is poured into the material transport pipe, so that a dense construction body with low moisture can be obtained as compared with the case of adding only conventional water. I understood it. The reason for this is that when the water stream collides to become atomized water, the water contains many fine bubbles uniformly in the water, so that the water can be easily separated into small particles at the time of collision, and finer atomized water is generated. It is estimated that the spray material can be moistened more uniformly.

  Moreover, compared with the case where the atomized water is injected with compressed air, even when a large amount of spraying is performed, the effect of obtaining a dense construction body with little rebound loss and the like can be obtained. This is considered to be because atomized water having the same size as that in the case of blowing in atomized water is generated even though compressed air is not required for water injection.

  Since the average particle diameter is as small as 100 μm or less, the size of the bubbles can be contained in a state of being uniformly dispersed in water, and it is easy to generate fine atomized water when colliding with water streams or spraying materials. When the size of the bubbles is larger than the average particle size of 100 μm, a large amount of construction water is required to obtain a good construction body with a poor kneading effect. A more preferable size of the bubbles is an average particle size of 50 μm or less.

  And the content rate to the construction water of a bubble shall be 0.1-30 volume% in order to acquire the uniform kneading | mixing effect with low moisture. Preferably it is 1-20 volume%. If it is less than 0.1% by volume, it is difficult to knead uniformly with low moisture, and if it exceeds 30% by volume, pulsation is likely to occur during spraying, and dust generation increases.

  The atomized water generated in this way has an average particle size of 100 μm or less. In the present invention, the atomized water having an average particle size of 100 μm or less may be generated when the construction water is poured in a state where only the air for conveying the material is supplied without supplying the spray material. In actual spraying construction, the spraying material is transported, and it is estimated that atomized water of 100 μm or less is generated not only by collision between water streams but also by collision between the material and construction water. In this way, since the atomized water is generated in the material conveying pipe, the specific surface area of water is increased, and the spray material can be remarkably uniformly wet compared with the conventional water addition method. A higher kneading effect can be obtained in a short time even for the powder of the spray material that moves at high speed in the transport pipe. In particular, the effect of more uniform wetting on the fine raw material powder is great. As a result, a dense construction body with low moisture can be obtained. Further, since the compressed air is not blown together with the atomized water, problems such as rebound loss due to an increase in the amount of compressed air do not occur even if the amount of spraying increases.

  As described above, the atomized water has an average particle size of 100 μm or less, preferably 70 μm or less, and more preferably 5 to 50 μm. This average particle diameter can be measured by a laser Doppler method. When the average particle size of the atomized water is larger than 100 μm, the specific surface area of water becomes small and the spray material becomes difficult to be uniformly moistened, and the water content varies depending on the location of the kneaded spray material. come. As a result, construction moisture increases in order to obtain a spray material with good workability.

  When the flow velocity of the water flow is higher, smaller atomized water is more likely to be generated due to the collision between the water flows or the collision between the water flow and the spray material, so that the water can be kneaded with low moisture. Moreover, the stirring effect of the spray material is further increased. For this reason, the flow velocity of the water flow is preferably 7 m / s or more (s: second), more preferably 10 m / s or more, and further preferably 15 m / s or more. When the water flow is less than 7 m / s, it is difficult to obtain fine atomized water, and it becomes difficult to knead with low moisture. Here, the flow velocity of the water flow referred to in the present invention is a value calculated from the amount of water supplied to the water injector per unit time and the cross-sectional area of the inner hole of the water inlet. In addition, sufficiently fine atomized water can be obtained by setting the upper limit of the flow velocity of the water flow to 50 m / s or less. If the pressure exceeds 50 m / s, the water pressure becomes high, and the water injector and the piping have a high pressure resistance specification and become expensive, but the effect of reducing moisture is small and impractical.

  In the present invention, the water inlet of the water injector can be a plurality of through holes having a circular cross section. The inner diameter is preferably 0.4 mm or more and 2 mm or less, and the water pressure is preferably 0.4 Mpa or more and 5 Mpa or less. If the inner diameter of the water injection port is less than 0.4 mm, the spray material is likely to be clogged, and if it exceeds 2 mm, the diameter of the water flow becomes too large and the atomized water tends to increase, making it difficult to obtain a uniform kneading effect. A more preferable inner diameter of the water inlet is 0.6 mm or more and 1.5 mm or less. On the other hand, if the water pressure is less than 0.4 Mpa, the flow rate of the water flow becomes slow, and it is difficult to obtain good atomized water, and the kneading effect is reduced. If the water pressure exceeds 5 Mpa, the water tends to be excessive. A more preferable range of the water pressure is 0.6 Mpa or more and 3 Mpa or less.

  Further, the water injection port for spraying the atomized water from the water injector can be a slit that is long in the circumferential direction. In the case of the slit, since the water sprayed from the water injection port is poured into the material transport pipe in a planar shape, it is easy to form a cap-shaped water flow or spray, and the atomized water and the raw material particles in the spray material The contact frequency can be increased. Furthermore, if it is made into a slit, it will be hard to clog spray material. A plurality of slits may be provided in the circumferential direction of the inner hole surface of the water injector, or one continuous slit may be used. The width of the opening of the slit is preferably 0.1 to 1 mm from the viewpoint of generating atomized water having an average particle size of 100 μm or less. If it is less than 0.1 mm, the slit is easily clogged with the spray material, and if it exceeds 1 mm, atomized water having an average particle diameter of 100 μm or less is hardly generated.

  In the present invention, in the material conveying pipe, a primary water injector is provided on the upstream side and a secondary water injector is provided on the downstream side, and water is injected from two locations. When the construction water is poured and the remaining construction water necessary for the construction is poured from the secondary water feeder, the water can be poured from at least the primary water feeder by any one of the above methods. Further, a dispersant or a binder can be added in advance to the water to be injected from the primary water injector. If the dispersant is dissolved in advance, it dissolves faster in water than in the case where the dispersant is mixed as a powder from the beginning, resulting in a lower moisture content.

  The kneading state of the spray material by the primary water injector aims at a state in which powder, water and air are continuous, that is, a Funicular region. The Funicular region is described in “Kneading Technology”, written by Kenji Hashimoto, published on October 5, 1978, by the Industrial Technology Center, and is a state that further categorizes powder, liquid and gas kneading states. It is a state where the liquid is sufficiently coated on the powder, but since the gas is continuous, the feeling that it is seen means that it is in a state of lumpyness. Specifically, it is a stage one step before becoming a slurry, and when the kneaded product is grasped by hand, it is solidified, but it is in a state where it is immediately unraveled. In general, irregular refractories containing dispersants are kneaded while adding water little by little, but at the beginning there is almost no change even when water is added. There is a quantity. The amount of construction water added in the primary water injector of the present invention is targeted at the amount of water added immediately before this sudden softening. This state is also a state where the kneaded material hardly spreads in the tap flow test, that is, a range of 100 to 110 mm. In the present invention, the amount of primary water injection varies depending on the type of refractory raw material, rapid setting agent, dispersant or binder used, particle size, amount added, etc., but the amount of water added is also a guideline for this tap flow value range. It can be. In other words, the tap flow value increases even if there is too little or too much moisture, but it is an intermediate state.

  Furthermore, microscopically, the raw material particles having a particle size of 75 μm or less are originally in the form of small secondary particles in which some raw material particles are gathered in the powder state, but in the case of water injection with the primary water injector of the present invention, It is considered that the raw material particles are wetted by the atomized water while maintaining the shape of the secondary particles. In the secondary particles, raw material particles having a particle size larger than 75 μm may exist as nuclei. In the present invention, since water is injected under the condition that the average particle size is 100 μm or less and very small atomized water is generated, the amount of water for one secondary particle is less than the amount of slurry or high even if the slurry is formed. It is considered to be a viscous value. For this reason, even if the secondary particles coalesce during conveyance, it is considered that it is difficult to form a slurry. Further, during the conveyance of the material, it is considered that the kneading effect is further added by the collision between the secondary particles, the secondary particles and particles of 75 μm or more, or the secondary particles and the inner surface of the material conveyance tube.

  As a result, a kneaded product having a low moisture content and an excellent kneading effect is obtained, and can be constructed with a minimum amount of moisture in a secondary water injector. Therefore, a kneaded material excellent in workability can be obtained with an extremely small amount of added water as compared with the conventional dry spraying method. Furthermore, since the spray material does not become a slurry state in the material conveying pipe, it is not clogged in the middle, so the material conveying pipe can be lengthened, for example, conveying a long distance of 30 m or more. Is also possible. In addition, since it does not adhere and accumulate in the material transfer tube, it does not require time for cleaning.

  On the other hand, in the case of atomized water having an average particle size larger than 100 μm, when the secondary particles are wetted, the amount of water with respect to one secondary particle is too much and the frequency of slurrying the secondary particles is considered to be high. It is done. As mentioned above, a slight difference in the water content causes slurrying (plowing). Therefore, when secondary particles having excessive moisture collide with secondary particles having an appropriate amount of moisture during conveyance, the slurry grows in a combined manner. As a result, slurry is locally generated in the conveying material. It is estimated that the spray material becomes a non-uniform mixture and the kneading effect is reduced, and the slurry adheres to the material conveying pipe.

  When the amount of water added by the primary water dispenser is less than 10% by mass of the amount of water necessary for spraying, the amount of water is small relative to the spray material, so the spray material is evenly moistened during transportation. Cannot be in a state. As a result, the amount of added water in the secondary water injector is increased by that amount, and a spray material that is not in a sufficiently kneaded state is sprayed, resulting in a deterioration in the quality of the construction body. On the other hand, if the amount exceeds 50% by mass, a large amount of moisture is present in the spray material kneaded during conveyance, so that a phenomenon that the kneaded material adheres to the material conveyance tube occurs.

  Further, the remaining construction water is added from the secondary water dispenser to the uniformly wetted and kneaded spray material, and more preferably atomized water having an average particle size of 100 μm or less is generated. By using atomized water having an average particle size of 100 μm or less, it is possible to wet the spray material being conveyed more uniformly as described above, so that a high kneading effect is obtained. For this reason, a high kneading effect can be obtained with a much smaller amount of water than in the conventional dry construction method, whereby a dense construction body with little rebound loss and high adhesion rate can be obtained.

  The secondary water injector is preferably provided immediately before the tip spray nozzle. By providing it immediately before, it is possible to reduce the time and effort of cleaning the material conveying pipe and to obtain a kneading effect in the tip spray nozzle. Note that the term “immediately before the spray nozzle” does not necessarily mean that the spray nozzle and the water injector are installed separately, but a secondary water injector may be attached to the spray nozzle itself, or it is integrated with the spray nozzle. It doesn't matter.

  Further, from this secondary water injector, the quick setting agent can be added to water and sprayed. By adding the quick-setting agent to water, the quick-setting agent can diffuse more quickly into the wet spraying material, and the reactivity is increased and the adhesion rate is improved.

  In the present invention, the kneading effect is further improved by providing a mixer near the secondary water injector of the material transport pipe. This is because when the spray material wetted by water injection from the primary water injector is transported in the material transport pipe, especially when the material transport pipe is long, the coarse raw material and the fine powder part are separated and segregation occurs. There are things to do. In order to restore this segle, a mixer is provided. With this mixer, a dense construction body without variations can be obtained. As the mixer, a general mixer such as a static mixer can be provided, but a mixing tube with a narrowed inner diameter is more preferable. A simple structure in which the inner diameter is reduced is preferable because there is no clogging of the material. The inner diameter d of the mixing tube is preferably 0.5D or more and less than 0.9D with respect to the inner diameter D of the material conveying tube.

  As a spraying material applicable to the construction method of the present invention, either a conventional wet spraying material or a dry spraying material can be used without any problem. When a conventional wet spraying material is used, a mixer for kneading is not required, and it is not necessary to clean the material conveying pipe after the operation, so that the construction method is remarkably excellent in workability. In addition, a dense construction body can be obtained with the same amount of added moisture as in the conventional wet construction method. Moreover, when the conventional dry-type spraying material is applied, a dense construction body with lower moisture can be obtained. For example, in the iron and steel industry, magnesia material spraying material for ladle and converter, magnesia-calcia material spraying material or magnesia-carbonaceous spraying material for converter, alumina-silicon carbide material spraying for firewood An alumina-magnesia material spraying material for ladle and ladle can be used. At this time, it is also possible to use construction water obtained by dissolving a quick setting agent, a dispersing agent and the like in water as atomized water.

  In particular, when the spray material is an alumina-silicon carbide amorphous refractory containing 5 to 30% by mass of silicon carbide having a particle size of 75 μm or less, it can be applied with low moisture. Silicon carbide that constitutes the alumina-silicon carbide amorphous refractory is a porous material that is difficult to wet with water, and this is the cause of the unfamiliarity between the alumina-silicon carbide amorphous refractory and construction water. is there. In the present invention, the construction water is atomized water having an average particle size of 100 μm or less, so that the atomized water is inserted into the porous structure of silicon carbide. Moreover, the ratio of the silicon carbide fine powder having a particle size of 75 μm or less in the refractory raw material composition is 5 to 30% by mass, so that the silicon carbide fine powder can contain the atomized water in the matrix of the amorphous refractory. That is, according to the present invention, the difficulty of wetting the construction water with respect to silicon carbide is mitigated by the insertion of atomized water into the porous structure of silicon carbide and the containment of atomized water in the matrix with silicon carbide fine powder. Is done. As a result, the amorphous refractory to which atomized water is added at the primary water injection point is promoted to mix until reaching the spray nozzle, and a uniform and dense construction body structure can be obtained.

  Furthermore, when the spray material contains 1 to 30% by mass of magnesia fine powder and the remainder is an alumina-magnesia amorphous refractory mainly composed of alumina, there is an effect of further improving the durability. In general, magnesia, which occupies a part of the refractory raw material composition in alumina-magnesia amorphous refractories, digests by reaction with construction moisture, weakens the refractory structure and causes a decrease in strength of the construction body. . In the present invention, as described above, the amorphous refractory has no contact with construction moisture for a long time, and the amount of construction water can be reduced, and digestion of magnesia in the alumina-magnesia amorphous refractory is suppressed. The strength of the spray construction body is improved. In addition, the construction body structure of the irregular refractory is densified by reducing the amount of construction water. This densification of the structure increases the contact area between alumina particles and magnesia particles in alumina-magnesia amorphous refractories, and promotes the formation of spinel due to the reaction between alumina and magnesia at high temperatures when using a sprayed body. Is done. The generation of this spinel has the effect of imparting strength by forming a spinel bond structure together with the slag resistance of the spinel itself.

  If the proportion of the magnesia fine powder in the composition of the refractory raw material is less than 1% by mass, the effect of the corrosion resistance of magnesia cannot be obtained, and the amount of spinel produced by the reaction with alumina is reduced and the effect of the slag resistance becomes insufficient. . If it exceeds 30% by mass, the proportion of magnesia fine powder with insufficient spinel formation reaction will increase during the use of the irregular refractory construction body, or the slag infiltrating layer will become thick and cause structural spalling Cause a decrease in durability. The specific particle size of the magnesia fine powder is, for example, 1 mm or less with a JIS standard sieve in order to improve the reactivity with alumina. More preferably, it is 150 μm or less. Further, fine particles such as 75 μm or less may be used.

  On the other hand, when the spray material is roughly classified according to the construction temperature, it can be divided into a cold spray material and a hot spray material. Cold and warm materials are used for new kiln lining or large-scale repairs, and the temperature of kilns and the like is kept in the range from room temperature to 600 ° C, and the hydration reaction proceeds during the curing time after construction. Connective tissue is generated. On the other hand, since the hot spray material is used for the purpose of small-scale repair during operation, the repair work is performed without cooling the kiln, so the temperature of the kiln or the like is 600 ° C or higher. It becomes work. A connective tissue is rapidly formed by evaporation of water immediately after construction and polymerization or condensation reaction of the binder.

  As a cold and warm spraying material constructed at a temperature of 600 ° C. or less, a binder composed of one kind of alumina cement, magnesia cement, phosphate or silicate with respect to the refractory raw material powder, a rapid setting agent, A blended composition obtained by adding and mixing a dispersant and fibers, containing 25-60 mass% of a raw material having a particle size of less than 75 μm in the refractory raw material powder, and of these, a raw material having a particle size of less than 10 μm / 75 μm By using a spray material in which the mass ratio of the raw material of less than 10 μm is 0.25 to 0.7, kneading can be performed with low moisture, and a dense construction body can be obtained.

  In the construction method of the present invention, as described above, the material after passing through the primary water injector is considered to be in a state of being dispersed and uniformly wet in units of secondary particles in a powder state. . These secondary particles contain a quick-setting agent, a dispersing agent and a binder, but the amount added is small, and they are uniformly mixed with other refractory raw material powders at the time of manufacture, so the frequency of contact with each other is extremely high. Low. For this reason, it is considered that most of the quick setting agent, the dispersing agent and the binder are present in the secondary particles without losing its effect. For this reason, the quick setting agent and the dispersant are hardly dissolved in water and diffused in a wide range while the material is being conveyed. Therefore, since the material does not aggregate, the amount of water does not increase. For this reason, it is not necessary to add the quick setting agent separately at the tip portion, and the complicated work of managing the addition amount of the quick setting agent and cleaning the material transport pipe is also unnecessary. In addition, a dense construction body with low moisture can be obtained.

  However, in the present invention, since the construction water is added under the condition that atomized water of 100 μm or less is generated, the wetting effect is very high. For this reason, while suppressing the dissolution and diffusion of the quick setting agent, the dispersing agent and the binder, In order to effectively add construction water, an ultrafine raw material having a large specific surface area of less than 10 μm is effective, and a balance with a raw material of less than 75 μm and 10 μm or more is important. That is, the mass ratio of the raw material of less than 10 μm / the raw material of less than 75 μm and 10 μm or more is preferably in the range of 0.25 to 0.7, and further in the range of 0.30 to 0.60, a denser construction body can be obtained. This is more preferable. If it is less than 0.25, it tends to agglomerate and the construction moisture increases, and if it exceeds 0.7, the powder tends to adhere to the material conveying tube.

  Moreover, if the usage-amount of the raw material less than 75 micrometers is less than 25 mass%, a precise construction body will be hard to be obtained, and when it exceeds 60 mass%, the durability of a construction body will fall.

  On the other hand, if fibers are added to this cold and warm spray material, there is an effect that the material is less likely to adhere to the material transport pipe. The reason for this is that the material being transported contains a lot of air due to the addition of fibers to form a bulky lump, which makes it easier to transport with air and makes it difficult to adhere to the inner surface of the material transport pipe. presume. On the other hand, since the construction body becomes dense, it is also effective as a countermeasure against explosions during drying.

  More preferably, the particle size composition of the cold and warm spray material is 20 to 45% by mass with a particle size of 5 mm or less and 1 mm or more, 10 to 40% by mass with a particle size of less than 1 mm and 75 μm or more, and 25 to 60% by mass with a particle size of less than 75 μm. Furthermore, with respect to 100 parts by mass of the refractory raw material powder having a mass ratio of the raw material of less than 10 μm / the raw material of less than 75 μm and 10 μm or more of 0.25 to 0.7, alumina cement, magnesia cement, 1-7 parts by mass of phosphate or silicate, 0.5-5 parts by mass of quick setting agent, 0.01-0.5 parts by mass of dispersant, and 0.05-0.5 of fiber It is a blended composition obtained by adding 0.5 parts by mass and mixing.

  The above is a case where the temperature at the time of construction is 600 ° C. or lower. However, preferable materials for the hot spraying material to be applied at a temperature of 600 ° C. or higher are thermosetting organic resin, phosphorous for the refractory raw material powder. A blended composition obtained by adding and mixing a binder consisting of one of acid salts or silicates, containing 10 to 45% by mass of a raw material having a particle size of less than 75 μm in the refractory raw material powder, Among them, the mass ratio of the raw material less than 10 μm / the raw material less than 75 μm and 10 μm or more is 0.25 to 0.7. Moreover, a quick setting agent can also be added as needed.

  This hot spray material is similar to the type that uses thermosetting organic resin, phosphate or silicate as a binder generally used in the conventional dry construction method, but in the structure of fine powder There are features. In other words, since the construction water is added under the condition that atomized water having an average particle size of 100 μm or less is generated, the fine powder raw material of less than 75 μm can be used in an amount of 10 to 45 mass% more than the conventional wet material, and as a result. There is an advantage that a very dense construction body can be obtained.

  In the present invention, since the construction water is added under the condition that atomized water having an average particle size of 100 μm or less is generated, the wetting effect is very high, and the ultrafine powder material having a large specific surface area of less than 10 μm is dense with low moisture. It is effective to obtain a simple construction body, and balance with a raw material of less than 75 μm and 10 μm or more is important. That is, the mass ratio of the raw material of less than 10 μm / the raw material of less than 75 μm and 10 μm or more is preferably in the range of 0.25 to 0.7, and further in the range of 0.30 to 0.60, a denser construction body can be obtained. This is more preferable. If it is less than 0.25, it tends to agglomerate and the construction moisture increases, and if it exceeds 0.7, the powder tends to adhere to the material conveying tube.

  Furthermore, the more preferable particle size constitution in the hot spray material is 20 to 45% by mass with a particle size of 5 mm or less and 1 mm or more, 20 to 45% by mass with a particle size of less than 1 mm and 75 μm or more, and 10 to 45% by mass with a particle size of less than 75 μm. In addition, the thermosetting organic resin, phosphorous as a binder on the outside with respect to 100 parts by mass of the refractory raw material powder having a mass ratio of the raw material of less than 10 μm / the raw material of less than 75 μm and 10 μm or more of 0.3 to 0.6 It is a blended composition formed by mixing 1 to 7 parts by mass of one or more of acid salts or silicates.

Further, in the spray construction method of the present invention, in the construction body constructed at room temperature, after curing for 24 hours or more at 110 ° C., the apparent porosity is 18 to 30% and the air permeability is 100 × 10 ⁻⁵ cm. ^When a spraying material of ³ · cm / cm ² · cmH ₂ O · sec or more is used, it is possible to obtain a construction body having a low moisture content and being dense and having excellent explosion resistance. The spraying material applied to the construction method of the present invention is designed on the premise of low moisture construction, so the apparent porosity is reduced, but explosion may easily occur during drying or hot spraying. is there. For this reason, an explosion can be prevented by setting it as the construction body which gave air permeability. If the apparent porosity is less than 18%, it becomes dense and tends to explode, and if it exceeds 30%, the corrosion resistance decreases. When the air permeability is less than 100 × 10 ⁻⁵ cm ³ · cm / cm ² · cmH ₂ O · sec, explosion tends to occur. A material that satisfies the above range can be obtained by optimizing the particle size configuration or adding an additive that enhances air permeability such as fibers. For example, it is obtained by adjusting the particle size constitution of 75 μm or less, and more specifically, it is obtained by setting the mass ratio of the raw material of less than 10 μm / the raw material of less than 75 μm and 10 μm or more in the range of 0.25 to 0.7. be able to.

  As the refractory raw material powder used for the spray material of the present invention, any refractory raw material used for general amorphous refractories can be used without any problem. For example, metal oxides, metal carbides, metal nitrides, carbons, metals and the like. In addition, if the maximum particle size of the refractory raw material powder exceeds 5 mm, separation and segle are likely to occur during conveyance after water injection by the primary water injector, and the kneading effect is reduced. More preferably, the raw material is 90% by mass or more, and even more preferably, the raw material having a particle size of 3 mm or less is 90% by mass or more in the refractory raw material powder.

  As a binder for the cold and warm spraying material, one of alumina cement, magnesia cement, phosphate or silicate can be used. Is more preferable.

  As the binder for the hot spraying material, one composed of one or more of thermosetting organic resin, phosphate or silicate can be used. A phenol resin or a furan resin can be used as the thermosetting organic resin.

  The dispersant is also referred to as a peptizer and can be used without any problem as long as it is used in general amorphous refractories. Has the effect of imparting fluidity during construction of irregular refractories. Specific examples include inorganic salts such as sodium tripolyphosphate, sodium hexametaphosphate, sodium ultrapolyphosphate, acid hexametaphosphate, sodium borate, sodium carbonate, polymetaphosphate, sodium citrate, sodium tartrate, sodium polyacrylate, Examples thereof include sodium sulfonate, polycarboxylate, β-naphthalenesulfonate, naphthalene sulfonic acid, carboxyl group-containing polyether dispersant, and the like.

  The rapid setting agent reacts with the binder in the presence of construction water to rapidly harden the amorphous refractory and impart adhesion to the amorphous refractory. The quick setting agent may be added to the amorphous refractory in the powder state from the beginning, or the quick setting agent may be added in the vicinity of the spray nozzle and in front of the secondary water injection point. When the quick setting agent is added at or near the spray nozzle, if necessary, the quick setting agent is used in a liquid diluted with water.

Specific examples of the quick setting agent include silicates such as sodium silicate and potassium silicate, aluminates such as sodium aluminate, potassium aluminate and calcium aluminate, sodium carbonate, potassium carbonate and sodium hydrogen carbonate. carbonates, sodium sulfate, potassium sulfate, sulfates such as magnesium _{sulfate, CaO · Al 2 O 3,} 12CaO · 7Al 2 O 3, CaO · 2Al 2 O 3, 3CaO · Al 2 O 3, 3CaO · 3Al 2 O Calcium aluminates such as ₃ · CaF ₂ , 11CaO · 7Al ₂ O ₃ · CaF ₂ , calcium salts such as calcium oxide, calcium hydroxide, and calcium chloride.

  However, as the quick setting agent used in the cold and warm spraying material of the present invention, sodium aluminate or slaked lime is more preferable from the viewpoint of excellent strength of the construction body. As the quick setting agent used in the hot spray material of the present invention, slaked lime, activated magnesia, or sulfate powder is more preferable from the viewpoint of excellent strength of the construction body.

  As the fiber, a fiber that is an ordinary amorphous refractory and used for the purpose of preventing explosion or the like can be used, and examples thereof include vinylon, nylon, PVA, polyvinyl, polystyrene, polypropylene, and carbon.

  By pouring the construction water containing 0.1 to 30% by volume of bubbles having an average particle size of 100 μm or less into the material transport pipe, a compact construction body with a low moisture content can be obtained compared to the case where only conventional water is added. Get.

  Since the water flow poured into the material transport pipe is constructed under the condition of atomized water with an average particle size of 100 μm or less, a good kneading effect can be obtained with low moisture, so a dense construction body with little variation can be obtained, and the furnace The lifespan is improved. In addition, a special kneading device such as a mixer is not required, and the material conveying pipe is not clogged, so that trouble during operation is reduced and cleaning work is reduced, so that the construction method is extremely excellent in workability. .

  When the spray material is an alumina-silicon carbide amorphous refractory containing 5-30% by mass of silicon carbide having a particle size of 75 μm or less, the familiarity with the construction water is better than the conventional construction method, Addition of construction water in the material transport pipe allows sufficient mixing of the amorphous refractory and construction water, improving adhesion and suppressing dust generation. And the denseness of a construction body improves.

  When the spray material contains 1 to 30% by mass of magnesia fine powder and the balance is an alumina-magnesia amorphous refractory mainly composed of alumina, the digestion of the construction body is promoted and the generation of spinel is promoted, so that the alumina-magnesia The volume stability and corrosion resistance effects of the amorphous refractories are fully demonstrated, and the durability of the sprayed construction is greatly improved.

  In addition, a mixture of a refractory raw material powder, which is made by adding a binder composed of one of alumina cement, magnesia cement, phosphate or silicate, a rapid setting agent, a dispersing agent, and fibers. The composition is a refractory raw material powder containing a raw material having a particle size of less than 75 μm in an amount of 25 to 60% by mass, and the mass ratio of the raw material of less than 10 μm / the raw material of less than 75 μm and 10 μm or more is 0.25 to 0.005. 7 is used, it is possible to knead with a small amount of added water compared to the conventional wet construction method, so that a high-quality construction body with little variation is obtained, and the life of the furnace is improved. . Furthermore, unlike the conventional case, there is almost no complicated work of managing the addition amount of the quick setting agent and cleaning of the material conveying pipe, and the work efficiency is improved.

  Furthermore, the composition is a composition obtained by adding a thermosetting organic resin, phosphate or silicate as a binder to the refractory raw material powder and mixing the raw material with a particle size of less than 75 μm in the refractory raw material powder. 10% to 45% by mass, and among these, when using a material in which the mass ratio of the raw material of less than 10 μm / the raw material of less than 75 μm and 10 μm or more is composed of 0.25 to 0.7, compared with the conventional dry construction method In addition, since it can be kneaded with a small amount of added water, a high-quality construction body with little variation is obtained, and the life of the furnace is improved. In addition, since a large dedicated mixer is not installed, the workability is excellent.

  Hereinafter, embodiments of the present invention will be described based on examples.

  FIG. 1 shows the overall configuration of a spraying device 10 for carrying out the method for spraying an irregular refractory according to the present invention.

  In the same figure, 1 shows the material supply machine in which the spraying material 2 was accommodated. As long as the material supply machine 1 is generally used in spraying devices for irregular refractories and can discharge a fixed amount, any type of a protector gun, lead gun, Nogami cement gun or the like can be used without any problem. it can.

  The spray material 2 in the material feeder 1 is adjusted from the material feeder 1 by a table feeder 3 whose internal pressure is adjusted by compressed air supplied into the material feeder 1 and driven by a motor M provided at the lower end. It is supplied to the transport hose 5 arranged up to the tip spray nozzle 4.

  Carrier air is supplied to the carrier hose 5 through the carrier air introduction portion 6 of the table feeder 3, and the spray material 2 from the material feeder 1 is sprayed from the tip spray nozzle 4 of the carrier hose 5 to the target body 9.

  The transport hose 5 is provided with a primary water injector 7 immediately after the material feeder 1 and a secondary water injector 8 immediately before the tip spray nozzle 4.

  The primary water injector 7 and the secondary water injector 8 generate atomized water in the transport hose 5, inject water into the spray material transported by air in two stages, and wet the spray material.

  Each water injector has a bubble generator 23. As the bubble generator 23, a microbubble generator that generates bubbles of 100 μm or less is used. There are various types of microbubble generators, and bubbles of several μm to several tens of μm are generated by supplying pressurized water and air (in some cases, pressurized air) into the apparatus and stirring them. These are generally commercially available. For example, an OHR line mixer manufactured by Seika Sangyo Co., Ltd., a micro-nano bubble generator from Nano Planet Research Laboratories, etc. can be used. Moreover, the density of bubbles can be increased by using a plurality of microbubble generators connected together. In the embodiment of FIG. 1, an OHR line mixer was used as the bubble generator 23.

  FIG. 2 shows the configuration of the water injector by a section cut along the transport hose 5. As the water injector, those having the same structure can be applied to the primary water injector 7 and the secondary water injector 8 shown in FIG.

  The water injector 7 (8) includes an outer cylinder 11 and an inner cylinder 12 provided therein. The water injector 7 (8) is fixed between the transport hoses 5 with a bolt (not shown) penetrating the water injector. The spray material is pneumatically conveyed in the conveyance hose 5 in the direction of the arrow in the figure. A pressure equalizing chamber 13 that is continuous in the circumferential direction is formed between the outer cylinder 11 and the inner cylinder 12 of the water injector as a reservoir so that the pressure of the pressurized water is uniform.

  The pressure equalizing chamber 13 is formed with a water injection port 14 inclined in the material conveying direction. As shown in FIG. 2, the water injection port 14 is formed so as to be inclined so that the angle α formed with the material traveling direction indicated by the arrow is 30 to 70 degrees toward the axis of the conveyance hose 5 in the conveyance direction. Has been. The water injection port of this embodiment has an inner diameter of 0.8 mm and an inclination angle α of 45 degrees, and a total of 12 water injection ports are provided at equal intervals along the circumferential direction.

  In the example of FIG. 2, twelve through holes having a circular cross section are provided as the water inlet, but instead of the twelve through holes, the water inlet may be a continuous slit as shown in FIG. 5. Is possible.

  The movement of atomized water indicated by the dotted line in FIG. 2 is a schematic diagram in which a transparent cylinder is connected to both sides of the water injector for the experiment, and a state where only pressurized water is supplied without introducing spray material is shown. Show. Water is discharged from the water injection port 14 as a water flow, collides with the central portion to become atomized water, and then flows almost in parallel to form a co-current spray flow A. In this state, when the material conveying air is supplied, the center of the collision becomes slightly large and unclear, but a co-sprayed co-current flow is formed. In the present invention, atomized water of 100 μm or less is generated in a state in which the material conveying air is supplied. In order to reduce the size of the atomized water to 100 μm or less in this state, the inner diameter, the inclination angle, the number of the water inlet, the flow velocity of the water flow discharged from the water inlet, the water pressure, and the like may be set as optimum conditions.

  FIG. 3 shows a mixing tube used in the present invention. The mixing tube 16 is a cylinder having flanges on both sides, and the inner hole is the same as the inner diameter D of the narrowed portion 17 having a smaller inner diameter than the material conveying tube 5, the tapered portions 18 on both sides thereof, and the material conveying tube on both sides thereof. It consists of a straight part 19. The inner diameter d of the throttle portion is 0.5D or more and 0.9D or less with respect to the inner diameter D of the material transport pipe. This mixing tube can be provided either before or after the secondary water injector. When this mixing tube is disposed before and after the secondary water injector, a kneading effect is further increased and a construction body with less variation is obtained.

  FIG. 4 shows an example of a bubble supply line which is another embodiment for generating construction water containing bubbles of 100 μm or less. Construction water containing bubbles of 100 μm or less generated in this bubble supply line is supplied to the water injector of the spray construction apparatus. In FIG. 4, a bubble generator 23 is connected to the bottom of a construction water tank 22 including a foam stabilizer introduction pipe 21 and a construction water introduction pipe 20. An air pipe 27 and a construction water circulation pipe 28 are connected to the bubble generator 23. The construction water circulation pipe 28 has a pressure reducing valve 24 and an opening / closing valve 25, and the other end is connected to a construction water boosting pump 29. The other construction water circulation pipe 28 is connected to the construction water booster pump 29. The other end of the other construction water circulation pipe 28 is connected to the bottom of the construction water tank 22. Here, the bubble generator 23 is for generating bubbles of 100 μm or less, and a commercially available device called a microbubble generator or the like can be used. In FIG. 4, a trade name OHR line mixer manufactured by Seika Sangyo Co., Ltd. was used. In this bubble supply line, pressurized water containing bubbles can be transported to the spray construction device via the flow rate adjustment valve 26. And the bubble stabilizer is suppressed by adding a bubble stabilizer from the bubble stabilizer introduction tube 21. The bubble stabilizer is added for the purpose of easily forming smaller bubbles and suppressing the coalescence and floating of the bubbles, and a known substance such as a surfactant can be used.

  The spraying by the spraying device 10 shown in the above drawings is performed in the following manner.

  First, similarly to the conventional dry-type spraying method, the spray material of the material feeder 1 is transported in the transport hose 5 by the transport air from the transport air introduction point 6. At the same time, the pressurized water is supplied to the construction water inlet 15 of the primary water injector 7 and the secondary water injector 8 through the bubble generator 23 to inject the sprayed material being conveyed by air. . The water flow injected from the water injector becomes atomized water by colliding with another water flow or spray material in the transport hose 5. This atomized water uniformly wets the spray material and kneads it uniformly.

  Then, the tip spray nozzle 4 is operated to spray the amorphous refractory sufficiently kneaded on the target body 9 such as a furnace wall.

  The distance interval between the primary water injector 7 and the secondary water injector 8 shown in FIG. 1 is not particularly limited, but it is preferable that the distance is somewhat apart from the viewpoint of the kneading effect. It is preferable to provide a distance of at least 1 m. That is, the primary water injector can be provided without any particular limitation as long as it is between 1 m or more upstream of the secondary water injector and the material feeder 1.

  The secondary water injector 8 can be provided in the front-end spray nozzle 4 body or in the vicinity thereof. If it is too far from the tip of the tip spray nozzle, the transport hose and the tip spray nozzle are likely to be clogged. The length of the transport hose is not particularly limited, and can be used without any problem as long as it is between 10 and 100 m, for example.

Table 1 shows spraying tests under various water injection conditions on a spraying material using 4 parts by weight of a powdered phenol resin as a binder against 100 parts by weight of magnesia clinker having a particle size adjusted as a refractory raw material powder. The results are shown. In addition, the water injector is provided only at one position at a position of 1.7 m from the tip of the tip spray nozzle, and the length of the tip spray nozzle is 1.5 m. Moreover, the flow rate of the air for conveying the spray material is 4.5 Nm ³ / min, the pressure is 0.25 MPa, the inclination angle of the water injection port of the water injection device is 45 degrees, the inner diameter of the material transfer pipe is 35 mm, and it is supplied to the water injection device The original pressure of the water to be used was 1.0 MPa. The amount of construction water was adjusted according to the spraying condition and the condition of the construction body. At this time, the average particle size of the atomized water was 21 μm (volume average particle size) as measured by the laser Doppler method in a state where only the air for supplying the spray material was supplied without supplying the spray material. In addition, a measurement position is a 300 mm downstream part from the water inlet of a water injector. As a measuring device for the particle size of atomized water, the trade name “AEROMETRICS” of TSI, USA was used. The test was performed by spraying a metal frame (depth 40mm, width 160mm, length 400mm) placed vertically at a position about 1m away in the horizontal direction, and examining the quality of the construction after drying at 110 ° C. It is.

Moreover, the average particle diameter of the bubble in construction water measured the average particle diameter by image | photographing and image-analyzing the water immediately after having come out of the bubble generator. The volume ratio of bubbles was calculated by supplying water and air to the bubble generator under the same conditions as the construction conditions, and measuring the volume before and after the water discharged in a certain time. As a result, the average particle diameter of the bubbles was 37 μm, and the ratio of the bubbles was 5% by volume.

  In Table 1, Examples 1 to 4 change the inner diameter of the water inlet and the flow velocity of the water flow, but are within the scope of the present invention, and a dense construction body with low moisture is obtained.

Next, the results of performing the spray test by the construction method shown in FIGS. 1 and 2 at the blending ratios shown in Table 2, Table 3, and Table 4 will be described. The primary water injector is located 20 m from the tip of the tip spray nozzle, the secondary water dispenser is 1.7 m from the tip of the tip spray nozzle, and the length of the tip spray nozzle is 1.5 m. Moreover, the flow rate of the air for conveying the spray material is 4.8 Nm ³ / min, the pressure is 0.27 MPa, the flow rate of the water flow of the primary water injector is 9.5 to 10 m / s, and the inner diameter of the water inlet is 0.8 mm. The number of water inlets is 8, the angle of inclination of the water inlet is 50 degrees, and the secondary water injector is the same value, the inner diameter of the water injector and the material transport pipe is 35 mm, the original pressure of the water supplied to each water injector is The pressure was 0.9 to 1.1 MPa. The amount of construction water was adjusted according to the spraying condition and the condition of the construction body. At this time, the average particle size of the atomized water was 24 μm (volume average particle size) as measured by the laser Doppler method in a state where only the air for supplying the spray material was supplied without supplying the spray material. In addition, a measurement position is a 300 mm downstream part from the water inlet of a water injector. Moreover, the average particle diameter of the bubble in construction water was 37 micrometers, and the ratio of the bubble was 5 volume%. The test was performed by spraying a metal frame (depth 40mm, width 160mm, length 400mm) placed vertically at a position about 1m away in the horizontal direction, and examining the quality of the construction after drying at 110 ° C. It is. The rotary erosion test was conducted in Table 2 using blast furnace slag at 1550 ° C. for 4 hours, and in Tables 3 and 4 using converter slag at 1650 ° C. for 4 hours to compare the remaining thicknesses of the test pieces. The measuring method of the air permeability was according to JISR2115.

Table 2 shows an example of a cold and warm spraying material. In an alumina-silicon carbide based spraying material using a refractory raw material powder containing 10% by mass of silicon carbide having a particle size of 75 μm or less and the balance being alumina, The result of investigating the influence on the construction body is shown. The binder, the quick setting agent, and the dispersing agent were in powder form, and a blended composition that was uniformly mixed with the refractory raw material powder and fibers in advance was used. In Examples 5 to 12, the ratio of the raw material having a particle size of less than 75 μm and the mass ratio of the raw material of less than 10 μm / the raw material of less than 75 μm and 10 μm or more are within the scope of the present invention, and a dense construction body with low moisture is obtained. ing. On the other hand, in Comparative Example 1, since the mass ratio of the raw material of less than 10 μm / the raw material of less than 75 μm and 10 μm or more is as small as 0.2, the rapid setting agent tends to agglomerate and the added moisture increases, so that a dense construction body is obtained. There wasn't. In Comparative Example 2, since the mass ratio of the raw material of less than 10 μm / the raw material of less than 75 μm and 10 μm or more is as large as 0.8, the material conveying tube becomes clogged and becomes unstable when the material is discharged from the nozzle. It was not obtained. Comparative Example 3 is a low-strength construction body due to a shortage of raw materials having a particle size of less than 75 μm. In Comparative Example 4, the corrosion resistance is poor because there are too many raw materials having a particle size of less than 75 μm.

Table 3 shows an example of a hot spray material, which is applied to a fine powder portion construction body in an alumina-magnesia material spray material using a refractory raw material powder containing 10% by mass of magnesia having a particle size of 75 μm or less and the balance being alumina. The result of investigating the impact is shown. The binder and the quick setting agent were in powder form, and a blended composition previously mixed with the refractory raw material powder was used. In Examples 13 to 20, the ratio of the raw material having a particle size of less than 75 μm and the mass ratio of the raw material of less than 10 μm / the raw material of less than 75 μm and 10 μm or more are within the scope of the present invention, and a dense construction body with low moisture is obtained. ing. On the other hand, in Comparative Example 5, since the mass ratio of the raw material of less than 10 μm / the raw material of less than 75 μm and 10 μm or more is as small as 0.2, the rapid setting agent tends to agglomerate and the added moisture increases, so that a dense construction body is obtained. There wasn't. In Comparative Example 6, since the mass ratio of the raw material of less than 10 μm / the raw material of less than 75 μm and 10 μm or more is as large as 0.8, the material conveyance tube becomes clogged and becomes unstable when the material is discharged from the nozzle. It was not obtained. In Comparative Example 7, the raw material having a particle diameter of less than 75 μm is insufficient, and the construction body has a low strength. In Comparative Example 8, the corrosion resistance is poor because there are too many raw materials having a particle size of less than 75 μm.

Table 4 shows an example of a hot spraying material using a phenol resin as a binder. In a spraying material of magnesia material containing 10% by mass of magnesia having a particle size of 75 μm or less, and the remainder using a refractory raw material powder composed of magnesia clinker. The result of having investigated about the influence which it has on the construction object of a fine powder part is shown. As the binder, a powdery composition was used, and a blended composition previously mixed with the refractory raw material powder was used. In Examples 21 to 28, the ratio of the raw material having a particle size of less than 75 μm and the mass ratio of the raw material of less than 10 μm / the raw material of less than 75 μm and 10 μm or more are within the scope of the present invention, and a dense construction body with low moisture is obtained. ing. On the other hand, in Comparative Example 9, since the mass ratio of the raw material of less than 10 μm / the raw material of less than 75 μm and 10 μm or more was as small as 0.2, the added moisture increased, so a dense construction body could not be obtained. In Comparative Example 10, since the mass ratio of the raw material of less than 10 μm / the raw material of less than 75 μm and 10 μm or more is as large as 0.8, the material conveyance tube becomes clogged and becomes unstable when the material is discharged from the nozzle. It was not obtained. In Comparative Example 11, the raw material having a particle size of less than 75 μm is insufficient, and the construction body has a low strength. In Comparative Example 12, the corrosion resistance is poor because there are too many raw materials having a particle size of less than 75 μm.

  INDUSTRIAL APPLICABILITY The present invention can be suitably used for spray repair and building of various parts of various metallurgical furnaces and ceramic furnaces.

The whole structure of the apparatus for enforcing the spray construction method of the irregular refractory of this invention is shown. The structure of the water injector used by this invention is shown. The cross section of a mixing tube is shown. The structure of a bubble supply line is shown. The 2nd Example of a water injector is shown.

Explanation of symbols

1 Material feeder 2 Spray material (dry refractory)
3 Table feeder
4 tip spray nozzle 5 transport hose 6 transport air introduction point 7 primary water injector 8 secondary water injector 9 target body 10 spraying device
DESCRIPTION OF SYMBOLS 11 Outer cylinder 12 Inner cylinder 13 Pressure equalization chamber 14 Water injection hole 15 Construction water introduction port 16 Mixing pipe 17 Restriction part 18 Taper part 19 Straight part 20 Construction water introduction pipe 21 Bubble stabilizer introduction pipe 22 Construction water tank 23 Bubble generator 24 Pressure reducing valve 25 Open / close valve 26 Flow rate adjusting valve 27 Air piping 28 Construction water circulation piping 29 Construction water booster pump

Claims (11)

  A spraying method for an irregular refractory that sprays and sprays construction water from a water injector to spray material transported in a material transport pipe, and has an average particle size of 100 μm or less from the water injector into the material transport pipe. Construction water containing 0.1 to 30% by volume of air bubbles is inclined 30 to 70 degrees with respect to the material transport direction, and injected so as to collide at almost the center in the material transport pipe, and atomized with an average particle size of 100 μm or less A method for spraying irregular refractories, characterized by generating water.   In the material transport pipe, a primary water dispenser is installed on the upstream side and a secondary water dispenser is installed on the downstream side, and the construction water is poured into the spray material from two locations. % Of the construction water, and the secondary water dispenser sprays the remaining construction water required for construction and sprays it. The construction water containing 0.1 to 30% by volume of bubbles of 100 μm or less is inclined by 30 to 70 degrees with respect to the material conveying direction, and poured so as to collide almost at the center in the material conveying pipe, and the average particle size is 100 μm or less. A method for spraying an irregular shaped refractory, characterized by generating atomized water.   The method for spraying an irregular refractory according to claim 1 or 2, wherein a flow rate of water injected from the water injector is 7 m / s or more.   The method for spraying an amorphous refractory according to any one of claims 1 to 3, wherein the spray material is an alumina-silicon carbide amorphous refractory containing 5 to 30 mass% of silicon carbide having a particle size of 75 µm or less. .   4. The spraying of the amorphous refractory according to any one of claims 1 to 3, wherein the spraying material is an alumina-magnesia amorphous refractory containing 1 to 30% by mass of magnesia fine powder and the balance being mainly alumina. Construction method.   A cold / warm spraying material that is applied in a cold / warm condition, and a binder composed of one of alumina cement, magnesia cement, phosphate or silicate, a rapid setting agent, and a dispersion for the refractory raw material powder. An additive and a fiber are added and mixed, and the raw material having a particle size of less than 75 μm is contained in the refractory raw material powder in an amount of 25 to 60% by mass, and among these, the mass ratio of the material less than 10 μm / the material less than 75 μm and 10 μm or more The spraying material used in the method for spraying an irregular refractory according to any one of claims 1 to 5, wherein is a 0.25 to 0.7.   It is a hot spraying material that is applied hot, and is a mixture of one or more of a thermosetting organic resin, phosphate or silicate as a binder to the refractory raw material powder, The refractory raw material powder contains 10 to 45% by mass of a raw material having a particle size of less than 75 μm, and the mass ratio of the raw material of less than 10 μm / the raw material of less than 75 μm and 10 μm or more is 0.25 to 0.7. The spray material used with the spray construction method of the irregular refractory according to any one of claims 1 to 5.   The spray material according to claim 6, wherein the binder is alumina cement, and the rapid setting agent is either sodium aluminate or slaked lime.   The spraying material according to claim 7, wherein the binder is phosphate or silicic acid, slaked lime, activated magnesia, or sulfate is used as the quick setting agent, and each is powder. In the construction body sprayed at room temperature, after curing and drying at 110 ° C. for 24 hours or more, the apparent porosity is 18 to 30% and the air permeability is 100 × 10 ⁻⁵ cm ³ · cm ² · cmH _2. It is O * sec or more, The spray material used with the spray construction method of the irregular refractory according to any one of claims 1 to 5. In the construction body sprayed at room temperature, after curing and drying at 110 ° C. for 24 hours or more, the apparent porosity is 18 to 30% and the air permeability is 100 × 10 ⁻⁵ cm ³ · cm ² · cmH _2. It is O * sec or more, The spraying material in any one of Claims 6-9.

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