JP5775112B2 - 鋳造体、キャスタブル組成物、及びそれらの製造方法 - Google Patents
鋳造体、キャスタブル組成物、及びそれらの製造方法 Download PDFInfo
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- JP5775112B2 JP5775112B2 JP2013118367A JP2013118367A JP5775112B2 JP 5775112 B2 JP5775112 B2 JP 5775112B2 JP 2013118367 A JP2013118367 A JP 2013118367A JP 2013118367 A JP2013118367 A JP 2013118367A JP 5775112 B2 JP5775112 B2 JP 5775112B2
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- 239000000203 mixture Substances 0.000 title claims description 176
- 238000004519 manufacturing process Methods 0.000 title description 2
- 239000002245 particle Substances 0.000 claims description 195
- 238000000465 moulding Methods 0.000 claims description 39
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 28
- 238000000034 method Methods 0.000 claims description 28
- 239000000463 material Substances 0.000 claims description 26
- 239000004568 cement Substances 0.000 claims description 6
- 238000007906 compression Methods 0.000 claims description 4
- 229910021487 silica fume Inorganic materials 0.000 claims description 2
- 239000011819 refractory material Substances 0.000 claims 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 25
- 238000005266 casting Methods 0.000 description 15
- 238000009826 distribution Methods 0.000 description 13
- 238000010438 heat treatment Methods 0.000 description 13
- 239000011159 matrix material Substances 0.000 description 12
- 239000007788 liquid Substances 0.000 description 9
- 239000011230 binding agent Substances 0.000 description 8
- 230000003247 decreasing effect Effects 0.000 description 8
- CPLXHLVBOLITMK-UHFFFAOYSA-N Magnesium oxide Chemical compound [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 5
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 4
- 239000013078 crystal Substances 0.000 description 4
- WGLPBDUCMAPZCE-UHFFFAOYSA-N Trioxochromium Chemical compound O=[Cr](=O)=O WGLPBDUCMAPZCE-UHFFFAOYSA-N 0.000 description 3
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 3
- 229910001570 bauxite Inorganic materials 0.000 description 3
- 230000009286 beneficial effect Effects 0.000 description 3
- 229910000423 chromium oxide Inorganic materials 0.000 description 3
- 238000001035 drying Methods 0.000 description 3
- 239000000395 magnesium oxide Substances 0.000 description 3
- 239000011236 particulate material Substances 0.000 description 3
- 235000011837 pasties Nutrition 0.000 description 3
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 2
- ILRRQNADMUWWFW-UHFFFAOYSA-K aluminium phosphate Chemical compound O1[Al]2OP1(=O)O2 ILRRQNADMUWWFW-UHFFFAOYSA-K 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 239000011362 coarse particle Substances 0.000 description 2
- 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 2
- 239000002270 dispersing agent Substances 0.000 description 2
- 239000002657 fibrous material Substances 0.000 description 2
- 210000003918 fraction a Anatomy 0.000 description 2
- 229910001338 liquidmetal Inorganic materials 0.000 description 2
- 229910052863 mullite Inorganic materials 0.000 description 2
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 2
- 229910010271 silicon carbide Inorganic materials 0.000 description 2
- 239000000377 silicon dioxide Substances 0.000 description 2
- 229910052851 sillimanite Inorganic materials 0.000 description 2
- 239000002002 slurry Substances 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 239000004604 Blowing Agent Substances 0.000 description 1
- MXRIRQGCELJRSN-UHFFFAOYSA-N O.O.O.[Al] Chemical compound O.O.O.[Al] MXRIRQGCELJRSN-UHFFFAOYSA-N 0.000 description 1
- 239000011398 Portland cement Substances 0.000 description 1
- YKTSYUJCYHOUJP-UHFFFAOYSA-N [O--].[Al+3].[Al+3].[O-][Si]([O-])([O-])[O-] Chemical compound [O--].[Al+3].[Al+3].[O-][Si]([O-])([O-])[O-] YKTSYUJCYHOUJP-UHFFFAOYSA-N 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- INJRKJPEYSAMPD-UHFFFAOYSA-N aluminum;silicic acid;hydrate Chemical compound O.[Al].[Al].O[Si](O)(O)O INJRKJPEYSAMPD-UHFFFAOYSA-N 0.000 description 1
- 229910052849 andalusite Inorganic materials 0.000 description 1
- 239000002518 antifoaming agent Substances 0.000 description 1
- 230000037237 body shape Effects 0.000 description 1
- XFWJKVMFIVXPKK-UHFFFAOYSA-N calcium;oxido(oxo)alumane Chemical compound [Ca+2].[O-][Al]=O.[O-][Al]=O XFWJKVMFIVXPKK-UHFFFAOYSA-N 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 239000006229 carbon black Substances 0.000 description 1
- 239000004927 clay Substances 0.000 description 1
- 230000001427 coherent effect Effects 0.000 description 1
- 230000000052 comparative effect Effects 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 230000006378 damage Effects 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 238000007872 degassing Methods 0.000 description 1
- 238000007580 dry-mixing Methods 0.000 description 1
- 238000005265 energy consumption Methods 0.000 description 1
- 230000001747 exhibiting effect Effects 0.000 description 1
- 239000000835 fiber Substances 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 239000010419 fine particle Substances 0.000 description 1
- 239000003517 fume Substances 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 239000010439 graphite Substances 0.000 description 1
- 229910002804 graphite Inorganic materials 0.000 description 1
- 230000008595 infiltration Effects 0.000 description 1
- 238000001764 infiltration Methods 0.000 description 1
- 150000002484 inorganic compounds Chemical class 0.000 description 1
- 229910010272 inorganic material Inorganic materials 0.000 description 1
- 239000010954 inorganic particle Substances 0.000 description 1
- 229910052850 kyanite Inorganic materials 0.000 description 1
- 239000010443 kyanite Substances 0.000 description 1
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 description 1
- 239000011859 microparticle Substances 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- RVTZCBVAJQQJTK-UHFFFAOYSA-N oxygen(2-);zirconium(4+) Chemical compound [O-2].[O-2].[Zr+4] RVTZCBVAJQQJTK-UHFFFAOYSA-N 0.000 description 1
- 239000004014 plasticizer Substances 0.000 description 1
- 229920001495 poly(sodium acrylate) polymer Polymers 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 230000035939 shock Effects 0.000 description 1
- 239000002893 slag Substances 0.000 description 1
- NNMHYFLPFNGQFZ-UHFFFAOYSA-M sodium polyacrylate Chemical compound [Na+].[O-]C(=O)C=C NNMHYFLPFNGQFZ-UHFFFAOYSA-M 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 229910052596 spinel Inorganic materials 0.000 description 1
- 239000011029 spinel Substances 0.000 description 1
- 229920001187 thermosetting polymer Polymers 0.000 description 1
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Description
1)最も粗い耐火性粒子画分が、乾燥組成物の50質量%以上を占める。この粒子画分は、少なくとも2の平方根または少なくとも2の、最大粒径に対する最小粒径の比率を有するギャップによって、より小さい粒子画分から分離される。例えば、最も粗い耐火性粒子画分は、500、800、または1000マイクロメートルよりも大きい粒径を有する粒子からなることができ、1000、2000、または4000マイクロメートル等の最大粒径を有する閉画分(closed fraction)であることができる。
(a)構造または鋳造成形物の大きさ及び形状に対応したキャビティを有するモールドを準備すること、
(b)キャビティに本発明のキャスタブル組成物を充填すること、
(c)所望により本発明のキャスタブル組成物に締固め及び/または振動を施すこと、
(d)キャスタブル組成物を硬化して鋳造形状、鋳造構造、または鋳造成形物を成形すること、並びに
(e)鋳造形状、鋳造構造、または鋳造成形物からモールドを分離すること、
のステップを含む。
本発明の組成物はまた、生の(wet)組成物がモールド内に置かれ機械プレスまたは水圧プレスまたは他の圧縮プロセスが施され所望形状の試料片または鋳造成形物が成形される、圧縮成形手順において使用され得る。
2. 2.8%以下の含水量で鋳造したときに、華氏230度に曝露した後に、未焼結状態において、1000ポンド/平方インチ(6,895kPa)以上の破壊係数を有する鋳造成形物を成形するキャスタブル組成物。
3. 2.8%以下の含水量で鋳造したときに、華氏230度に曝露した後に、未焼結状態において、3000ポンド/平方インチ(2,0684kPa)以上の冷間圧縮強さを有する鋳造成形物を成形するキャスタブル組成物。
4. 該鋳造成形物が、華氏230度に曝露した後に、10体積%以下の空孔率を有する、1に記載のキャスタブル組成物。
5. 該鋳造成形物が、華氏230度に曝露した後に、9体積%以下の空孔率を有する、1に記載のキャスタブル組成物。
6. 該鋳造成形物が、華氏230度に曝露した後に、8体積%以下の空孔率を有する、1に記載のキャスタブル組成物。
7. 該鋳造成形物が、華氏230度に曝露した後に、7体積%以下の空孔率を有する、1に記載のキャスタブル組成物。
8. 該鋳造成形物が、華氏230度に曝露した後に、6体積%以下の空孔率を有する、1に記載のキャスタブル組成物。
9. 該鋳造成形物が、華氏230度に曝露した後に、5体積%以下の空孔率を有する、1に記載のキャスタブル組成物。
10. 該鋳造成形物が、華氏230度に曝露した後に、4体積%以下の空孔率を有する、1に記載のキャスタブル組成物。
11. 該鋳造成形物が、華氏230度に曝露した後に、3体積%以下の空孔率を有する、1に記載のキャスタブル組成物。
12. 該空孔率が華氏1500度に曝露した後に得られる、1、4、5、6、7、8、9、10、及び11のいずれか1つに記載のキャスタブル組成物。
13. 該鋳造成形物が、華氏230度に曝露した後に、2000ポンド/平方インチ(13,790kPa)以上の破壊係数を有する、2に記載のキャスタブル組成物。
14. 該鋳造成形物が、華氏230度に曝露した後に、3000ポンド/平方インチ(20,684kPa)以上の破壊係数を有する、2に記載のキャスタブル組成物。
15. 該鋳造成形物が、華氏230度に曝露した後に、4000ポンド/平方インチ(27,579kPa)以上の破壊係数を有する、2に記載のキャスタブル組成物。
16. 該破壊係数値が華氏1500度に曝露した後に得られる、2、13、14、及び15のいずれか1つに記載のキャスタブル組成物。
17. 該鋳造成形物が、華氏230度に曝露した後に、5000ポンド/平方インチ(34MPa)以上の冷間圧縮強さを有する、3に記載のキャスタブル組成物。
18. 該鋳造成形物が、華氏230度に曝露した後に、8000ポンド/平方インチ(55MPa)以上の冷間圧縮強さを有する、3に記載のキャスタブル組成物。
19. 該鋳造成形物が、華氏230度に曝露した後に、10000ポンド/平方インチ(69MPa)以上の冷間圧縮強さを有する、3に記載のキャスタブル組成物。
20. 該鋳造成形物が、華氏230度に曝露した後に、12000ポンド/平方インチ(83MPa)以上の冷間圧縮強さを有する、3に記載のキャスタブル組成物。
21. 該冷間圧縮強さが華氏1500度に曝露した後に得られる、3、17、18、19、及び20のいずれか1つに記載のキャスタブル組成物。
22. 乾燥組成物の少なくとも50質量%を含む最も粗い耐火性粗粒画分を特徴とする、1〜21のいずれか1つに記載のキャスタブル組成物であって、少なくとも2の平方根の、最大粒径に対する最小粒径の比率を有するギャップによって、該最も粗い耐火性粗粒画分がより小さい粒子画分から分離された、キャスタブル組成物。
23. 該組成物が少なくとも4つの粒子画分を含み、そのうちの3つの隣接した粒子画分が、少なくとも2の平方根の粒径比を有するギャップによって分離され、該3つの隣接した粒子画分が、各々のすぐ接している大きい側の粒径画分に対して、粒径が減少する順番で、値がより小さい、より大きい、及びより小さい残存質量パーセントを有する、1〜21のいずれか1つに記載のキャスタブル組成物。
24. 該組成物が少なくとも4つの粒子画分を含み、そのうちの3つの隣接した粒子画分が、少なくとも2の平方根の粒径比を有するギャップによって分離され、該3つの隣接した粒子画分が、各々のすぐ接している大きい側の粒径画分に対して、粒径が減少する順番で、値がより大きい、より小さい、及びより大きい残存質量パーセントを有する、1〜21のいずれか1つに記載のキャスタブル組成物。
25. 該組成物が、少なくとも2の平方根の粒径比を有するギャップによって分離された少なくとも2つの粒子画分を含み、該少なくとも2つの粒子画分は、全てが100マイクロメートル未満の直径を有する粒子からなる、1〜21のいずれか1つに記載のキャスタブル組成物。
26. 該組成物が、少なくとも2の平方根の粒径比を有するギャップによって分離された少なくとも3つの粒子画分を含み、該少なくとも3つの粒子画分は、全てが100マイクロメートル未満の直径を有する粒子からなる、1〜21のいずれか1つに記載のキャスタブル組成物。
27. 該組成物が、少なくとも2の平方根の粒径比を有するギャップによって分離された少なくとも4つの粒子画分を含み、残存質量パーセントが、該少なくとも4つの粒子画分のそれぞれにおいて少なくとも40%である、1〜21のいずれか1つに記載のキャスタブル組成物。
28. 該組成物が、少なくとも2の平方根の粒径比を有するギャップによって分離された少なくとも5つの粒子画分を含む、1〜21のいずれか1つに記載のキャスタブル組成物。
29. 該ギャップの少なくとも2つがそれぞれ、乾燥組成物の質量の10質量%未満を含む、23〜28のいずれか1つに記載のキャスタブル組成物。
30. 該ギャップの少なくとも2つがそれぞれ、乾燥組成物の質量の5質量%未満を含む、23〜28のいずれか1つに記載のキャスタブル組成物。
31. 該鋳造成形物が、理論密度の少なくとも80.7%である密度を有する、1〜30のいずれか1つに記載のキャスタブル組成物。
32. 該鋳造成形物が、理論密度の少なくとも83.6%である密度を有する、1〜31のいずれか1つに記載のキャスタブル組成物。
33. 少なくとも95質量%のアルミナを含む、1〜32のいずれか1つに記載のキャスタブル組成物。
34. 該鋳造成形物が、華氏230度に曝露した後に、少なくとも190ポンド/立方フィート(3,044kg/m 3 )のかさ密度を有する、33に記載のキャスタブル組成物。
35. 該鋳造成形物が、華氏230度に曝露した後に、少なくとも195ポンド/立方フィート(3,124kg/m 3 )のかさ密度を有する、33に記載のキャスタブル組成物。
36. 該鋳造成形物が、華氏230度に曝露した後に、少なくとも200ポンド/立方フィート(3,204kg/m 3 )のかさ密度を有する、33に記載のキャスタブル組成物。
37. 該鋳造成形物が、華氏230度に曝露した後に、少なくとも202ポンド/立方フィート(3,236kg/m 3 )のかさ密度を有する、33に記載のキャスタブル組成物。
38. 該鋳造成形物が、華氏230度に曝露した後に、少なくとも207ポンド/立方フィート(3,316kg/m 3 )のかさ密度を有する、33に記載のキャスタブル組成物。
39. 該かさ密度が華氏1500度に曝露した後に測定される、34〜36のいずれか1つに記載のキャスタブル組成物。
40. 1〜39のいずれか1つに記載のキャスタブル組成物から成形された鋳造成形物。
41.鋳造成形物を成形する方法であって、
(a)該成形物の大きさ及び形状に対応したキャビティを有するモールドを準備すること、
(b)該キャビティに1〜39のいずれか1つに記載のキャスタブル組成物を充填すること、
(c)所望により本発明の該キャスタブル組成物に締固め及び/または振動を施すこと、
(d)該キャスタブル組成物を硬化して該鋳造成形物を成形すること、並びに
(e)該鋳造成形物から該モールドを分離すること、
を含む、方法。
42. 鋳造成形物を成形する方法であって、
(a)該成形物の大きさ及び形状に対応したキャビティを有するモールドを準備すること、
(b)該キャビティに1〜39のいずれか1つに記載のキャスタブル組成物を充填すること、
(c)本発明の該キャスタブル組成物を圧縮工程に送ること、
(d)該キャスタブル組成物を硬化して該鋳造成形物を成形すること、並びに
(e)該鋳造成形物から該モールドを分離すること、
を含む、方法。
Claims (14)
- 耐火性材料を含むキャスタブル組成物であって、
a)100マイクロメートル未満の直径を有する粒子からなる第1の粒子画分;
b)100マイクロメートル未満の直径を有する粒子からなり、前記第1の粒子画分よりも小さい第2の粒子画分;
c)100マイクロメートル超の粒径からなる第3の粒子画分;及び
d)100マイクロメートル超の粒径からなり、前記第3の粒子画分よりも小さい第4の粒子画分、
を含み、
前記第3の粒子画分及び前記第4の粒子画分が、少なくとも2の平方根の、最大粒径に対する最小粒径の粒径比を有するギャップによって分離された、
キャスタブル組成物。 - 100マイクロメートル未満の直径を有する粒子からなり、前記第2の粒子画分よりも小さい第5の粒子画分をさらに含む、請求項1に記載のキャスタブル組成物。
- 100マイクロメートル未満の直径を有する粒子からなり、前記第5の粒子画分よりも小さい第6の粒子画分をさらに含む、請求項2に記載のキャスタブル組成物。
- 100マイクロメートル未満の直径を有する粒子からなり、前記第6の粒子画分よりも小さい第7の粒子画分をさらに含む、請求項3に記載のキャスタブル組成物。
- 該第1の粒子画分、該第2の粒子画分、該第3の粒子画分、及び該第4の粒子画分が、アルミナ及びSecar(登録商標)セメントからなる群から選択される材料を含む、請求項1に記載のキャスタブル組成物。
- 4乾燥質量パーセント超の100マイクロメートル未満の直径を有する粒子を含む、請求項1に記載のキャスタブル組成物。
- 13乾燥質量パーセント超の100マイクロメートル未満の直径を有する粒子を含む、請求項1に記載のキャスタブル組成物。
- シリカヒュームをさらに含む、請求項1に記載のキャスタブル組成物。
- 前記第3の粒子画分が、乾燥組成物の少なくとも50質量%を含む、請求項1に記載のキャスタブル組成物。
- 該ギャップが、乾燥組成物の10質量%未満を含む、請求項1に記載のキャスタブル組成物。
- 該ギャップが、乾燥組成物の5質量%未満を含む、請求項1に記載のキャスタブル組成物。
- 少なくとも95乾燥質量%のアルミナを含む、請求項1に記載のキャスタブル組成物。
- 鋳造成形物を成形する方法であって、
(a)該成形物の大きさ及び形状に対応したキャビティを有するモールドを準備すること、
(b)該キャビティに請求項1に記載のキャスタブル組成物を充填すること、
(c)所望により本発明の該キャスタブル組成物に締固め及び/または振動を施すこと、
(d)該キャスタブル組成物を硬化して該鋳造成形物を成形すること、並びに
(e)該鋳造成形物から該モールドを分離すること、
を含む、方法。 - 鋳造成形物を成形する方法であって、
(a)該成形物の大きさ及び形状に対応したキャビティを有するモールドを準備すること、
(b)該キャビティに請求項1に記載のキャスタブル組成物を充填すること、
(c)本発明の該キャスタブル組成物を圧縮工程に送ること、
(d)該キャスタブル組成物を硬化して該鋳造成形物を成形すること、並びに
(e)該鋳造成形物から該モールドを分離すること、
を含む、方法。
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BRPI0816138A2 (pt) | 2015-02-24 |
US20130249136A1 (en) | 2013-09-26 |
AR101418A2 (es) | 2016-12-14 |
JP2010537933A (ja) | 2010-12-09 |
CN101790499B (zh) | 2015-07-15 |
US8470088B2 (en) | 2013-06-25 |
TWI455773B (zh) | 2014-10-11 |
RU2485076C2 (ru) | 2013-06-20 |
CA2844168C (en) | 2015-11-03 |
CN101790499A (zh) | 2010-07-28 |
MX351861B (es) | 2017-10-30 |
KR101458252B1 (ko) | 2014-11-04 |
EP2197811A4 (en) | 2011-07-27 |
RU2010106233A (ru) | 2011-10-10 |
KR20100068404A (ko) | 2010-06-23 |
AU2008293522B2 (en) | 2014-01-16 |
CA2844168A1 (en) | 2009-03-05 |
UA100859C2 (uk) | 2013-02-11 |
AU2008293522A1 (en) | 2009-03-05 |
EP2197811A1 (en) | 2010-06-23 |
US20100222201A1 (en) | 2010-09-02 |
JP2013199427A (ja) | 2013-10-03 |
ZA201000881B (en) | 2011-04-28 |
WO2009029704A1 (en) | 2009-03-05 |
AR068135A1 (es) | 2009-11-04 |
MX2010002302A (es) | 2010-03-18 |
CA2698243C (en) | 2014-07-08 |
US8821633B2 (en) | 2014-09-02 |
CA2698243A1 (en) | 2009-03-05 |
TW200918205A (en) | 2009-05-01 |
CN104844228A (zh) | 2015-08-19 |
JP5519505B2 (ja) | 2014-06-11 |
CN104844228B (zh) | 2017-12-05 |
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