JP6754653B2 - How to make checker bricks for hot air ovens - Google Patents
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本発明は、熱風炉の蓄熱室内に組み込まれる熱風炉用チェッカーれんが（以下、単に「チェッカーれんが」ともいう。）の製造方法に関する。 The present invention relates to a method for manufacturing a checker brick for a hot air furnace (hereinafter, also simply referred to as “checker brick”) incorporated in a heat storage chamber of the hot air furnace.
製銑用の高炉への熱風供給を行うために、熱風炉が用いられている。熱風炉の蓄熱室内には、蓄熱材として、外形が六角柱形状をしたチェッカーれんが（ギッターれんがともいう。）が多数配列され、複数層に重ねて築造されている。チェッカーれんがは、耐火れんが材で形成された六角柱形状の本体を有する。本体の上面及び下面は平行とされている。本体には、断面形状が丸形又は六角形のガス流路が複数、鉛直方向に貫通形成されており、各々は本体の上下面に開口されている。 A hot air furnace is used to supply hot air to a blast furnace for iron making. In the heat storage chamber of the hot air furnace, a large number of checkered bricks (also called gigter bricks) having a hexagonal columnar outer shape are arranged as heat storage materials, and are constructed by stacking them in multiple layers. The checkered brick has a hexagonal columnar body made of refractory brick material. The upper and lower surfaces of the main body are parallel. A plurality of gas flow paths having a round or hexagonal cross section are formed through the main body in the vertical direction, and each is opened on the upper and lower surfaces of the main body.
このようなチェッカーれんがでは、ガス流路に高温の燃焼ガスを通過させることで、本体のガス流路以外の耐火れんが材が詰まった部分（壁）に熱を蓄熱することができる。一方、蓄熱した状態でガス流路に冷風を通過させて熱交換させることで、高温の熱風を生成し、高炉に供給することができる。このとき、チェッカーれんがの寸法形状が、ガスと耐火れんが材との熱交換効率に大きな影響を与える。このため、近年では、ガス流路の形状及び壁の厚み等に関する最適化が行われ、孔の数を増やし壁の厚みが小さいものが開発されている。 In such a checkered brick, heat can be stored in a portion (wall) filled with refractory brick material other than the gas flow path of the main body by passing a high-temperature combustion gas through the gas flow path. On the other hand, by passing cold air through the gas flow path in a stored heat state to exchange heat, high-temperature hot air can be generated and supplied to the blast furnace. At this time, the size and shape of the checkered brick have a great influence on the heat exchange efficiency between the gas and the refractory brick material. For this reason, in recent years, optimization has been performed on the shape of the gas flow path, the wall thickness, and the like, and those with an increased number of holes and a small wall thickness have been developed.
例えば特許文献１には、１９個のガス流路を有し、壁の厚みが１５ｍｍのチェッカーれんがが開示されている。しかしながら、壁の厚みを薄くすると、従来の製造方法では成形中に成形体に亀裂が生じやすい問題、及び製品の強度が不十分となる問題が生じてくる。 For example, Patent Document 1 discloses a checkered brick having 19 gas channels and a wall thickness of 15 mm. However, if the wall thickness is reduced, the conventional manufacturing method causes a problem that the molded body is liable to crack during molding and a problem that the strength of the product becomes insufficient.
また、特許文献２には、コークス炉の蓄熱れんがであるが、スリットタイプで壁の厚みが１１ｍｍのものが開示されている。この蓄熱れんがの製造方法として、その段落００４３に「ボールミルで粉砕したムライトとコランダムを主材としてＡｌ２Ｏ３量７５ｗｔ％のハイアルミナ質蓄熱レンガを製作した。原料配合構成は粗粒（１．５〜０．８ｍｍ）、中粒（０．８〜０．０８ｍｍ）、細粒（＜０．０８ｍｍ）を１：２：２の比率としたもので、別にフリントクレイ３ｗｔ％、水分４ｗｔ％を添加したもので、３５０トンのフリクションプレスにて成形した」ことが記載されている。 Further, Patent Document 2 discloses a heat storage brick of a coke oven, which is a slit type and has a wall thickness of 11 mm. As a method for producing the heat storage brick, it was fabricated amount of Al 2 O 3 75 wt% of high alumina heat storage bricks mullite and corundum trituration with "ball in its paragraph 0043 as main material. Raw material compounding configuration coarse (1. 5 to 0.8 mm), medium grain (0.8 to 0.08 mm), fine grain (<0.08 mm) in a ratio of 1: 2: 2, and separately flint clay 3 wt% and moisture 4 wt%. It was added and molded with a 350 ton friction press. "
しかしながら、特許文献２の原料配合構成で特許文献１のチェッカーれんがを製造しようとすると、成形時に成形体に亀裂が生じる問題や焼成後の強度が不十分な問題がある。すなわち、チェッカーれんがの製造方法では成形時に孔を形成するために六角柱又は円柱の芯棒を使用することになるが、壁の厚みが薄いため成形後にこれらの芯棒を成形体から抜く際に壁が崩れたり、あるいは亀裂が生じたりする問題がある。また、特許文献２の蓄熱れんがは厚み１４．５〜１８ｍｍの長方形の枠を有しており、この枠によって強度が維持できるが、特許文献１のチェッカーれんがの場合には、全ての壁の厚みが１５ｍｍと薄いため、ハンドリング時の欠け等の破損が生じやすく、製品自体の強度を高める必要もある。 However, when an attempt is made to manufacture the checkered brick of Patent Document 1 with the raw material compounding composition of Patent Document 2, there is a problem that the molded body is cracked during molding and there is a problem that the strength after firing is insufficient. That is, in the checker brick manufacturing method, hexagonal column or cylindrical core rods are used to form holes at the time of molding, but since the wall thickness is thin, when these core rods are pulled out from the molded body after molding. There is a problem that the wall collapses or cracks occur. Further, the heat storage brick of Patent Document 2 has a rectangular frame having a thickness of 14.5 to 18 mm, and the strength can be maintained by this frame, but in the case of the checkered brick of Patent Document 1, the thickness of all the walls. Since the thickness is as thin as 15 mm, damage such as chipping during handling is likely to occur, and it is necessary to increase the strength of the product itself.
本発明が解決しようとする課題は、成形時の亀裂が発生することなく、しかも製品の強度が十分な熱風炉用チェッカーれんがの製造方法を提供することにある。 An object to be solved by the present invention is to provide a method for producing a checkered brick for a hot air furnace, which does not cause cracks during molding and has sufficient product strength.
成形時の強度を向上するためには耐火原料配合物への粘土の使用が有効であるが、その反面、焼成収縮が大きくなり亀裂が入る問題がある。本発明者らはシリマナイト族鉱物を併用することで焼成中の亀裂が防止できることを知見した。その結果、壁の厚みが薄くても成形時の亀裂の発生がなく、しかも製品の強度が十分あるチェッカーれんがの製造方法に想到した。 It is effective to use clay in the fire-resistant raw material formulation in order to improve the strength at the time of molding, but on the other hand, there is a problem that the firing shrinkage becomes large and cracks occur. The present inventors have found that cracks during calcination can be prevented by using a sillimanite group mineral in combination. As a result, we came up with a method for manufacturing checkered bricks, which does not cause cracks during molding even if the wall thickness is thin and has sufficient product strength.
すなわち、本発明の熱風炉用チェッカーれんがの製造方法は、ムライト原料１０〜５０質量％、コランダム含有原料２０〜６０質量％、シリマナイト族鉱物としてアンダルサイト、カイアナイト、及びシリマナイトのうち１種又は２種以上１０〜３０質量％、及び粘土３〜２０質量％からなり、ムライト原料、コランダム含有原料、アンダルサイト、カイアナイト、及び／又はシリマナイトのうち粒径０．２ｍｍ以下の原料が５〜２０質量％である耐火原料配合物を混練後、成形し、乾燥、焼成するもので、特に耐火原料配合物の構成に特徴がある。以下、本発明による耐火原料配合物の構成について詳しく説明する。 That is, the method for producing a checkered brick for a hot air furnace of the present invention comprises 10 to 50% by mass of a mullite raw material, 20 to 60% by mass of a corundum-containing raw material, and one or two of andalusite, caianite, and sillimanite as sillimanite group minerals. It is composed of 10 to 30% by mass and 3 to 20% by mass of clay, and 5 to 20% by mass of raw materials having a particle size of 0.2 mm or less among mullite raw materials, corundum-containing raw materials, andalusite, caianite, and / or silimanite. A certain fire-resistant raw material compound is kneaded, then molded, dried, and fired. The composition of the fire-resistant raw material compound is particularly characteristic. Hereinafter, the constitution of the fireproof raw material compound according to the present invention will be described in detail.
コランダム含有原料は耐クリープ性向上及び強度発現のために２０〜６０質量％で使用する。コランダム含有原料が２０質量％未満では耐クリープ及び強度が不十分となり、６０質量％を超えると耐スポーリング性が低下する。 The corundum-containing raw material is used in an amount of 20 to 60% by mass for improving creep resistance and developing strength. If the corundum-containing raw material is less than 20% by mass, the creep resistance and strength are insufficient, and if it exceeds 60% by mass, the spalling resistance is lowered.
ムライト原料は、耐クリープ性及び耐スポーリング性向上のために１０〜５０質量％で使用する。ムライト原料が１０質量％未満では耐クリープ性及び耐スポーリング性が不十分となり、５０質量％を超えると耐スポーリング性の向上効果は変わらず逆に原料費のコストアップとなる。 The mullite raw material is used in an amount of 10 to 50% by mass for improving creep resistance and spalling resistance. If the mullite raw material is less than 10% by mass, the creep resistance and spalling resistance are insufficient, and if it exceeds 50% by mass, the effect of improving the spalling resistance does not change, and conversely, the raw material cost increases.
ムライト原料、コランダム含有原料、アンダルサイト、カイアナイト、及び／又はシリマナイトのうち粒径０．２ｍｍ以下の原料は成形時の充填性を高めることで組織を緻密化し焼成後のれんがのボロツキや欠けを防止するために５〜２０質量％使用する。この粒径０．２ｍｍ以下の原料が５質量％未満では、焼成後に壁部のエッジ部のボロツキや欠けが発生し、２０質量％を超えると組織が緻密になりすぎて耐スポーリング性が低下する。 Of the mullite raw materials, corundum-containing raw materials, andalsite, caianite, and / or sillimanite, the raw materials having a particle size of 0.2 mm or less improve the filling property at the time of molding to densify the structure and prevent the rags and chips of the bricks after firing. 5 to 20% by mass is used. If the amount of the raw material having a particle size of 0.2 mm or less is less than 5% by mass, the edge portion of the wall portion may be raged or chipped after firing, and if it exceeds 20% by mass, the structure becomes too dense and the spalling resistance is lowered. To do.
シリマナイト族鉱物としてアンダルサイト、カイアナイト、あるいはシリマナイトは、それ自身が焼成中に膨張することから、粘土の使用による焼成中のれんがの収縮を抑制することで焼成収縮による亀裂の発生を抑制する効果がある。シリマナイト族鉱物としてアンダルサイト、カイアナイト、及びシリマナイトのうち１種又は２種以上は１０〜３０質量％で使用する。これらのシリマナイト族鉱物が１０質量％未満では焼成亀裂の抑制効果が不十分であり、３０質量％を超えると熱膨張率が高くなり過ぎて耐スポーリング性が不十分となる。 Andalusite, kyanite, or sillimanite as a sillimanite group mineral expands during calcination, so it has the effect of suppressing the shrinkage of bricks during calcination due to the use of clay, thereby suppressing the occurrence of cracks due to calcination shrinkage. is there. As a sillimanite group mineral, one or more of andalusite, kyanite, and sillimanite are used in an amount of 10 to 30% by mass. If these sillimanite group minerals are less than 10% by mass, the effect of suppressing calcination cracks is insufficient, and if they exceed 30% by mass, the coefficient of thermal expansion becomes too high and the spalling resistance becomes insufficient.
粘土は成形時に成形体の強度を高め亀裂を防止するためと焼成後の強度発現のために３〜２０質量％使用する。粘土が３質量％未満では成形体の強度が不十分なため成形体に亀裂が発生し、２０質量％を超えると焼成収縮が大きくなり焼成時に亀裂が発生する。焼成後の強度をさらに高くしたい場合、粘土は１０質量％以上、すなわち１０〜２０質量％使用することが好ましい。 Clay is used in an amount of 3 to 20% by mass in order to increase the strength of the molded product during molding to prevent cracks and to develop the strength after firing. If the clay content is less than 3% by mass, the strength of the molded product is insufficient and cracks occur in the molded product. If the clay content exceeds 20% by mass, the firing shrinkage becomes large and cracks occur during firing. When it is desired to further increase the strength after firing, it is preferable to use clay in an amount of 10% by mass or more, that is, 10 to 20% by mass.
さらに本発明においては、粘土の多量使用による過焼結を防止するために、耐火原料配合物中のＦｅ２Ｏ３を１．５質量％以下、及びＮａ２Ｏを１．０質量％以下とすることが好ましい。 Further, in the present invention, in order to prevent oversintering due to the large use of clay, Fe 2 O 3 in the fireproof raw material formulation is set to 1.5% by mass or less, and Na 2 O is set to 1.0% by mass or less. It is preferable to do so.
本発明によれば、成形時の亀裂が発生することなく、しかも製品の強度が十分な熱風炉用チェッカーれんがを製造することができる。 According to the present invention, it is possible to manufacture a checkered brick for a hot air furnace in which cracks do not occur during molding and the strength of the product is sufficient.
本発明において耐火原料配合物に使用するコランダム含有原料としては、コランダムを５０質量％以上含有する原料のうち１種以上を使用することができる。例えば電融アルミナ、焼結アルミナ、ボーキサイト、焼バンケツ、仮焼アルミナ及びれんが屑のうち１種以上を使用することができる。 As the corundum-containing raw material used in the fire-resistant raw material formulation in the present invention, one or more of the raw materials containing 50% by mass or more of corundum can be used. For example, one or more of fused alumina, sintered alumina, bauxite, baked banquet, calcined alumina and brick waste can be used.
ムライト原料としては、通常の耐火物の原料として市販されているものを使用することができ、例えば合成ムライト、電融ムライト、あるいは焼結ムライトなどを使用することができる。ムライトは、不純物としてコランダムあるいはクリストバライトを含むことがあり、ムライト純度が８５％以上のものを使用することが好ましい。 As the mullite raw material, commercially available raw materials for ordinary refractories can be used, and for example, synthetic mullite, fused mullite, sintered mullite, or the like can be used. The mullite may contain corundum or cristobalite as impurities, and it is preferable to use a mullite having a mullite purity of 85% or more.
粘土としては、通常の耐火物の原料として市販されているものを使用することができ、例えばＳｉＯ２含有量が４０〜７０質量％、Ａｌ２Ｏ３含有量が２０〜３０質量％のものなどを使用することができる。 As the clay, commercially available clay can be used as a raw material for ordinary refractories. For example, clay having a SiO 2 content of 40 to 70% by mass and an Al 2 O 3 content of 20 to 30% by mass can be used. Can be used.
シリマナイト族鉱物としては、シリマナイト、アンダルサイト及びカイアナイトのうち１種又は２種以上を使用する。これらのシリマナイト族鉱物の熱膨張率はいずれも、ムライト、シャモット、及びアルミナの熱膨張率より大きいので、粘土の使用による焼成中のれんがの収縮を抑制することで焼成収縮による亀裂の発生を抑制する効果がある。これらの原料は、天然から採掘される鉱物であり、それらを精製して使用することができる。より耐クリープ性を確保したい場合には、不純物としての酸化鉄（Ｆｅ２Ｏ３）が約２質量％以下、好ましくは１質量％以下とすることもできる。 As the sillimanite group mineral, one or more of sillimanite, andalusite and kyanite are used. Since the coefficient of thermal expansion of all of these silimanite minerals is larger than the coefficient of thermal expansion of mullite, chamotte, and alumina, the occurrence of cracks due to calcination shrinkage is suppressed by suppressing the shrinkage of bricks during calcination due to the use of clay. Has the effect of These raw materials are minerals mined from nature, and they can be purified and used. When it is desired to secure more creep resistance, iron oxide (Fe 2 O 3 ) as an impurity can be contained in an amount of about 2% by mass or less, preferably 1% by mass or less.
なお、上記以外の原料でも悪影響を及ぼさない範囲で耐火原料配合物に使用することができ、例えばろう石、珪石、溶融シリカ、シャモット等は１０質量％以下、好ましくは５質量％以下で使用可能である。 It should be noted that raw materials other than the above can be used in refractory raw material formulations as long as they do not adversely affect them. For example, pyrophyllite, silica stone, molten silica, chamotte and the like can be used in an amount of 10% by mass or less, preferably 5% by mass or less. Is.
本発明のチェッカーれんがの製造方法では、以上の構成を有する耐火原料配合物を使用し、後は一般的なチェッカーれんがの製造方法を採用することができる。すなわち、耐火原料配合物にバインダーを添加して混練、成形、乾燥後、１３００〜１６００℃で焼成することができる。 In the checkered brick manufacturing method of the present invention, a fireproof raw material compound having the above constitution can be used, and then a general checkered brick manufacturing method can be adopted. That is, a binder can be added to the fire-resistant raw material compound, kneaded, molded, dried, and then fired at 1300 to 1600 ° C.
そして本発明によれば、熱風炉で使用されている公知形状のチェッカーれんがのほか、より熱交換効率に優れる薄壁のチェッカーれんが、例えば壁の厚みが１０ｍｍ以上１５ｍｍ未満で、孔の数が７〜３７個程度のチェッカーれんがを問題なく製造することができる。 According to the present invention, in addition to the checker bricks of known shapes used in hot air furnaces, thin-walled checker bricks having more excellent heat exchange efficiency, for example, have a wall thickness of 10 mm or more and less than 15 mm and a number of holes of 7. About 37 checker bricks can be manufactured without any problem.
表１及び表２に示す耐火原料配合物に水系のバインダーを添加して混練し、プレス機で図１に示すチェッカーれんがを成形し、乾燥後、１４００℃で焼成した。図１のチェッカーれんがは、壁の厚みＴが１１ｍｍ、れんがの高さＨが１３０ｍｍ、れんがの１辺（六角形状の外形の１辺）の長さＬが１３０ｍｍ、孔の数が１９個である。 A water-based binder was added to the fire-resistant raw material formulations shown in Tables 1 and 2, and the mixture was kneaded. The checkered brick shown in FIG. 1 was formed by a press machine, dried, and then fired at 1400 ° C. The checkered brick of FIG. 1 has a wall thickness T of 11 mm, a brick height H of 130 mm, a brick side (one side of a hexagonal outer shape) length L of 130 mm, and a number of holes of 19. ..
コランダム含有原料として使用した焼バンケツは、コランダムが８０質量％のものを使用した。同じくコランダム含有原料として使用したれんが屑は、コランダムが５０質量％、鉱物相としてのムライトが４０質量％のものを使用した。ムライト原料として使用した合成ムライトは、鉱物としてのムライトが９２質量％のものを使用した。シリマナイト族鉱物としてのアンダルサイトはＡｌ２Ｏ３含有量が６０質量％、ＳｉＯ２含有量が３７質量％のものを、カイアナイトはＡｌ２Ｏ３含有量が５８質量％、ＳｉＯ２含有量が３９質量％のものを、シリマナイトはＡｌ２Ｏ３含有量が７５質量％、ＳｉＯ２含有量が２０質量％のものを使用した。粘土は、Ａｌ２Ｏ３含有量が２５質量％、ＳｉＯ２含有量が５５質量％のものを使用した。 As the baked banquet used as the corundum-containing raw material, one having 80% by mass of corundum was used. Similarly, as the brick waste used as the raw material containing corundum, 50% by mass of corundum and 40% by mass of mullite as the mineral phase were used. As the synthetic mullite used as a raw material for mullite, one having 92% by mass of mullite as a mineral was used. Andalsite as a sillimanite group mineral has an Al 2 O 3 content of 60% by mass and a SiO 2 content of 37% by mass, and kyanite has an Al 2 O 3 content of 58% by mass and a SiO 2 content of 39% by mass. As for silimanite, one having an Al 2 O 3 content of 75% by mass and one having a SiO 2 content of 20% by mass was used. The clay used had an Al 2 O 3 content of 25% by mass and a SiO 2 content of 55% by mass.
上述のとおり表１及び表２に示す耐火原料配合物に水系のバインダーを添加して混練し、プレス機で図１に示すチェッカーれんがを成形し、乾燥後、１４００℃で焼成したが、この際、成形時の亀裂と焼成後の外観を評価した。
成形時の亀裂は、１０個成形した後の表面の状態を目視で観察し１個でも亀裂があれば×とし、亀裂がないものを○とした。
焼成後の外観は、前記の１０個成形したれんがを焼成した後の表面の状態を目視で観察し１個でも亀裂又は壁部のボロツキがあれば×とし、亀裂又は壁部のボロツキがないものを○とした。
As described above, a water-based binder was added to the fire-resistant raw material formulations shown in Tables 1 and 2, kneaded, the checkered brick shown in FIG. 1 was formed by a press, dried, and then fired at 1400 ° C. , Cracks during molding and appearance after firing were evaluated.
As for the cracks at the time of molding, the state of the surface after molding 10 pieces was visually observed, and if there was even one crack, it was evaluated as x, and the one without cracks was evaluated as ◯.
The appearance after firing shall be marked as x if there is any crack or rags on the wall by visually observing the state of the surface after firing the above 10 molded bricks, and there is no crack or rags on the wall. Was marked as ○.
また、焼成後の図１のチェッカーれんがから図２のサンプルを切り出し、圧縮強さを測定するとともに、クリープ試験及びスポーリング試験を行った。図２のサンプルの寸法は、Ａ、Ｂ及びＣが７４ｍｍで、高さが６０ｍｍである。
圧縮強さはＪＩＳ−Ｒ２２０６に従い測定した。
クリープ試験はＪＩＳ−Ｒ２６５８に従い１３００℃で５時間、０．２ＭＰａの条件で実施し、クリープ値が１％以下のものを○とし、１％を超えるものを×とした。
スポーリング試験はＪＩＳ−Ｒ２６５７に従い８００℃加熱後の水冷法により、２０回実施し、２０回後でも剥落がないものを○、２０回までに剥落のあったものを×とした。
なお、焼成後に亀裂が入った比較例では、亀裂が入っていないれんがの圧縮強さのみを測定し、スポーリング試験とクリープ試験は行っていない。
Further, the sample of FIG. 2 was cut out from the checkered brick of FIG. 1 after firing, the compressive strength was measured, and a creep test and a spalling test were performed. The dimensions of the sample in FIG. 2 are 74 mm for A, B and C and 60 mm in height.
Compressive strength was measured according to JIS-R2206.
The creep test was carried out at 1300 ° C. for 5 hours under the condition of 0.2 MPa according to JIS-R2658, and those having a creep value of 1% or less were evaluated as ◯, and those exceeding 1% were evaluated as x.
The spalling test was carried out 20 times by a water cooling method after heating at 800 ° C. according to JIS-R2657. Those that did not peel off even after 20 times were marked with ◯, and those that had peeled off by 20 times were marked with x.
In the comparative example in which cracks were formed after firing, only the compressive strength of the bricks without cracks was measured, and the spalling test and the creep test were not performed.
実施例１から実施例３はアンダルサイトの使用量が異なる場合であるがいずれも良好であった。これに対して比較例１はアンダルサイトの使用量が５質量％と本発明の下限値を下回っており、焼成後に１０個中５個のれんがに亀裂が発生した。また、比較例２はアンダルサイトの使用量が３５質量％と本発明の上限値を超えておりスポーリング試験では１７回で剥落し、耐スポーリング性に問題があった。 In Examples 1 to 3, the amount of andal site used was different, but all were good. On the other hand, in Comparative Example 1, the amount of andalusite used was 5% by mass, which was lower than the lower limit of the present invention, and 5 out of 10 bricks were cracked after firing. Further, in Comparative Example 2, the amount of andalusite used was 35% by mass, which exceeded the upper limit of the present invention, and was peeled off after 17 times in the spalling test, and there was a problem in spalling resistance.
実施例４から実施例７は粘土の使用量が異なる場合であるがいずれも良好であった。なお、実施例４は成形時及び焼成後の亀裂は発生しなかったが成形中に亀裂が入らないように成形中の取り扱いに注意が必要であった。また、実施例４の焼成後の強度は実用上問題ないレベルではあるがやや低くなった。これに対して、比較例３は粘土の使用量が１質量％と本発明の下限値を下回っており、成形時の強度不足のため成形後に１０個中４個のれんがに亀裂が発生し、焼成後には１０個中６個のれんがに亀裂が発生した。また、亀裂のないれんがの圧縮強さを測定したところ３０ＭＰａと低強度で実用上問題のあるレベルであった。一方、比較例４は粘土の使用量が２５質量％と本発明の上限を超えており、焼成収縮が大きすぎるため焼成後に１０個中３個のれんがに亀裂が発生した。 Although the amounts of clay used in Examples 4 to 7 were different, they were all good. In Example 4, cracks did not occur during molding and after firing, but care must be taken in handling during molding so that cracks do not occur during molding. In addition, the strength of Example 4 after firing was slightly low, although it was at a level where there was no problem in practical use. On the other hand, in Comparative Example 3, the amount of clay used was 1% by mass, which was lower than the lower limit of the present invention, and 4 out of 10 bricks cracked after molding due to insufficient strength during molding. After firing, 6 out of 10 bricks cracked. Moreover, when the compressive strength of the brick without cracks was measured, it was as low as 30 MPa, which was a practically problematic level. On the other hand, in Comparative Example 4, the amount of clay used was 25% by mass, which exceeded the upper limit of the present invention, and the firing shrinkage was too large, so that 3 out of 10 bricks cracked after firing.
実施例８から実施例１０は粒径０．２ｍｍ以下のムライト原料の使用量が異なる場合であるがいずれも良好な結果となった。これに対して、比較例５は粒径０．２ｍｍ以下のムライト原料を使用しない場合であり、焼成後の圧縮強さは十分あるが、焼成後のれんがの１０個中５個に壁部のエッジ部にボロツキや欠けが発生した。また、比較例６は粒径０．２ｍｍ以下のムライト原料の使用量が２５質量％と本発明の上限を超えており、組織が緻密になりすぎてスポーリング試験では１８回で剥落し耐スポーリン性に問題があった。 In Examples 8 to 10, the amounts of mullite raw materials having a particle size of 0.2 mm or less were different, but all of them gave good results. On the other hand, Comparative Example 5 is a case where a mullite raw material having a particle size of 0.2 mm or less is not used, and although the compressive strength after firing is sufficient, 5 out of 10 bricks after firing have wall portions. Brick or chipping occurred on the edge. Further, in Comparative Example 6, the amount of the mullite raw material having a particle size of 0.2 mm or less used was 25% by mass, which exceeded the upper limit of the present invention, and the structure became too dense to be peeled off in 18 times in the spalling test to withstand spallin. There was a problem with sex.
実施例１１はシリマナイト族鉱物としてカイヤナイトを、実施例１２はシリマナイト族鉱物としてシリマナイトをそれぞれ使用した場合であるが、アンダルサイトを使用した場合と同様に良好な結果となった。 Example 11 was a case where cayanite was used as a sillimanite group mineral, and Example 12 was a case where sillimanite was used as a sillimanite group mineral. However, good results were obtained as in the case of using andalusite.
実施例１３と実施例１４は粒径０．２ｍｍ以下のコランダム含有原料として焼バンケツを使用した場合、実施例１５は粒径０．２ｍｍ以下の原料として焼バンケツと合成ムライトとを、実施例１６は粒径０．２ｍｍ以下の原料として焼バンケツと合成ムライトとアンダリュサイトを、併用した場合であるが、いずれも粒径０．２ｍｍ以下のムライト原料を単独で使用した場合と同様に、組織が緻密になり焼成後のれんがのボロツキや欠けもなく良好であった。 In Examples 13 and 14, when a baked banquet was used as a corundum-containing raw material having a particle size of 0.2 mm or less, in Example 15, a baked banquet and synthetic mullite were used as a raw material having a particle size of 0.2 mm or less, and Example 16 Is a case where a baked banquet, synthetic mullite, and andalusite are used in combination as raw materials having a particle size of 0.2 mm or less, but in each case, the structure is the same as when a mullite raw material having a particle size of 0.2 mm or less is used alone. It became dense and the bricks after firing were good without any rags or chips.
次に、実施例４及び実施例７と同じ耐火原料配合物を使用して図１において壁の厚みが１５ｍｍ及び１０ｍｍのチェッカーれんがの製造を行ったところ、成形後及び焼成後の亀裂はなく良好であった。 Next, when the checkered bricks having wall thicknesses of 15 mm and 10 mm in FIG. 1 were produced using the same fire-resistant raw material formulations as in Examples 4 and 7, there were no cracks after molding and firing, which was good. Met.
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