JPH05141872A - Sheet-shaped joint material for piling refractory brick and fabrication thereof - Google Patents

Abstract

PURPOSE:To rapidly and accurately ensure refractory brick piling without requiring skill by forming and employing a refractory brick piling sheet-shaped joint material by mixing a muddy material comprising refractory fine powder and a thickener into a fibrous texture of an unwoven fabric. CONSTITUTION:A refractiory brick piling sheet-shaped joint material is fabricated by mixing a muddy material 2 comprising refractory powder and a thickener into a fibrous texture of an unwoven fabric 3. The joint is sheet-shaped, so that once it is fabricated into a predetermined thick one, a uniform thickness joint is formed with ease upon piling bricks by simply sticking to refractory bricks thereamong. Further, the unwoven fabric 3 has a cushioning property, and when it is pushed by the refractory bricks, part of the molding part 2 contained in the fibrous texture of the unwoven fabric 3 exudes and diffused between the joint material and the refractory brick for securely burying gaps thereamong therewith.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a joint material used for stacking refractory bricks and a method for manufacturing the joint material.

[0002]

2. Description of the Related Art Conventionally, the lining of industrial kilns exposed to high temperatures is lined with refractory bricks. The bricks on this lining have mortar as a joint material,
Refractory bricks are glued together.

The thickness of the joint material must be determined according to the usage conditions of the industrial furnace, the type of refractory bricks, etc., and the joint material must be constructed accurately and uniformly. Therefore, the conventional brick loading work has been performed by skilled workers.

[0004]

However, due to the recent labor shortage, it has become difficult to secure skilled workers. For this reason, bricks are being piled up by mechanization in some areas.However, due to problems such as poor speed and accuracy with the current mechanization technology and a large loss of mortar used for joint-insertion processes, I had no choice but to rely on my human resources.

Mortar as a joint material is roughly classified into a water system and a non-water system. The water system is used by adding a thickener such as clay to a binder and further adding water at the time of construction. For the non-aqueous type, a liquid resin or the like is used as a binder (JP-A-54-19, etc.).

[0006] These mortars are required to have workability such as spread of the iron and separation of the iron. However, if the waiting time after kneading is long, the proper viscosity necessary for the workability is lost. Kneading is performed. If kneading alone is not sufficient, water or binder is added again. For this reason, there are problems that the construction is troublesome, and that the porosity is increased due to the re-addition of water or the binder, so that the corrosion resistance and the adhesive strength are reduced.

An object of the present invention is to solve the above-mentioned problems of the prior art and to provide a joint material which enables rapid and accurate joint formation without resorting to skilled workers. Another object is to provide a method for efficiently manufacturing this joint material.

[0008]

SUMMARY OF THE INVENTION The present invention is a sheet-shaped joint material for refractory bricks in which a fibrous structure of a non-woven fabric contains a sludge containing fine refractory powder and a thickener.
The invention of the manufacturing method is characterized in that the above-mentioned sludge is included in the fiber structure of the nonwoven fabric by the pressure action of the pressure roller.

Since the joint material of the present invention is in the form of sheet, if the joint material having a predetermined thickness is prepared in advance, the joint material having a uniform thickness can be simply attached between the refractory bricks when the bricks are stacked. Can be easily formed. In addition, when the non-woven fabric is pressed by refractory bricks due to its cushioning property, part of the mud sludge contained in the fibrous structure of the non-woven fabric exudes and diffuses between the joint material and the refractory brick, filling the voids securely . Therefore, the joint can be formed quickly and accurately without requiring skill.

A nonwoven fabric is used in this invention. In addition to these fibers, there are, for example, cloth woven fabrics and short fibers, but the cloth woven fabrics are less likely to include sludge in their fiber structure, and sludge easily falls off during handling of the joint material. In addition, since it is difficult for the sludge to be included, the pore size caused by the burning is large, and the corrosion resistance and the adhesive strength of the joint material are lowered.

On the other hand, in the material in which the short fibers are mixed, since the fibers are independent from each other, the joint material cannot have sufficient flexibility and strength, is easily torn during handling, and has poor adhesive strength. There are drawbacks.

On the other hand, the joint material of the present invention using a non-woven fabric has a fine and non-directional fibrous structure of the non-woven fabric so that the contained sludge does not fall off and Adhesive strength is high due to the integration of.
Further, it is supported by the fibrous structure and has an effect that tearing does not occur during handling.

The material of the non-woven fabric is formed by intertwining one or a plurality of organic fibers, carbon fibers, glass fibers, and ceramic fibers by, for example, the needle punch method or the spunbond method. Among them, the organic fiber is carbonized when heated in the operation of the furnace, and the joint material has a carbon bond structure. As a result, it is more preferable in terms of corrosion resistance and adhesive strength.

Organic fibers are vegetable fibers such as cotton and hemp,
There are recycled fibers such as rayon and cupra, semi-synthetic fibers such as acetate, and synthetic chemical fibers such as vinylon, polyacrylonitrile, and polyethylene terephthalate.

The thickness of the non-woven fabric is determined according to the joint width of the brick stack. The joint material of the present invention has a cushioning property of the non-woven fabric when pressed by a refractory brick, and a part of the mud contained in the fiber structure of the non-woven fabric exudes, diffuses between the joint material and the refractory brick, and forms voids. Although it has an effect of filling a portion, the shrinkage ratio required for it is preferably 5 to 70% when the thickness before shrinkage is 100%. If it is less than 5%, the above effect due to the cushioning property is insufficient. If it exceeds 70%, the shrinkable width becomes too large and it becomes difficult to control the joint width.

The material of the refractory fine powder to be dispersed in the sludge is not particularly limited.
The main material is one or more selected from silica, silica-alumina, magnesia, spinel, zircon, zirconia, silicon carbide, and carbon. Examples of the alumina material include synthetic mullite, bauxite, sillimanite, andalusite, kyanite, fused alumina, sintered alumina, and calcined alumina. As magnesia, sintered magnesia made of natural or synthetic raw materials,
They are electrofused magnesia and calcined magnesia. Carbonaceous materials include scaly graphite, earthy graphite, pitch coke, carbon black and anthracite. The particle size of the refractory fine powder is set to, for example, 0.03 to 0.3 mm so that it is easily included in the fiber structure of the nonwoven fabric.

Examples of the thickener include clay, acrylic acid emulsion, polyacrylic acid and salts thereof, methylcellulose.
Cellulose and cellulose derivatives such as hydroxymethyl cellulose, polyvinyl alcohols, polyvinyl butyral and the like are used alone or in combination. When these thickeners are used to obtain sludge, a solvent such as water is added at the same time. For example, a thickening agent of 0.1 to 30% by weight and the balance consisting of refractory fine powder are added to the mixture to give water of 5
Add ~ 30% by weight to make mud. Further, a mixture of a thickener and water may be added to the refractory fine powder in advance.

A liquid resin may be used as the thickener. As an example of the liquid resin, any one kind or plural kinds of phenol resin, furan resin, epoxy resin, urea resin, melanin resin, benisoguanamine resin and the like are used.
The liquid resin also includes a liquid resin liquefied. The usage ratio is a ratio in the sludge, for example, 5 to 80% by weight.

In addition to the above-mentioned refractory fine powder and thickener, if necessary, for example, metal powder, silica flour, glass powder, short fibers and the like may be added. The metal powder is one kind or several kinds selected from silicon, aluminum, magnesium, calcium, chromium, zirconium, iron or alloys thereof.

In the joint material of the present invention, the fibrous structure of the non-woven fabric contains the sludge comprising the above refractory fine powder and the thickener. The method for producing this joint filler material is not particularly limited, but by utilizing the pressure action of the pressure roller, it is possible to continuously include the sludge in the fibrous structure of the non-woven fabric, and industrial mass production is possible. It will be possible. 1 and 2
[Fig. 3] is a schematic view showing a manufacturing method using a pressure roller. Figure 1 shows a container (4) containing sludge (2)
The non-woven fabric (3) is passed through a pressure roller (1) therein. In FIG. 2, the nonwoven fabric (3) is passed through the pressure roller (1) while supplying the sludge (2).

[0021]

EXAMPLES Examples of the present invention and comparative examples will be described below.

[0022]

[Table 1]

[0023]

[Table 2]

Table 1 shows examples and comparative examples of the alumina joint material. In Examples 1 to 4, the sludge was included in a non-woven fabric having a thickness of 5 mm with a pressure roller. Comparative Example 1 is a mortar having the composition shown in the table. In Comparative Example 2, a plate-like joint material was manufactured by pressing the mortar materials shown in the table. In Comparative Example 3, the sludge shown in the table has a thickness of 5 m.
m cotton cloth fabric.

Table 2 shows examples and comparative examples of the magnesia joint material. In Examples 5 to 8, the sludge having the composition shown in the table was included in a non-woven fabric having a thickness of 5 mm with a pressure roller. Comparative Example 4 is a mortar having the composition shown in the table.

The tests in Tables 1 and 2 were measured as follows.

Construction time: The time required for stacking 100 bricks using the joint material of each example in the brick stacking by the normal-type refractory bricks.

Accuracy of joint thickness: In brick stacking with normal refractory bricks, a brick thickness of 1 mm is obtained with a joint thickness of 3 mm.
The number of joints with an error of 1 mm or more when stacking 00.

Corrosion resistance: The inner layer of the rotary drum has a thickness of 10
A refractory brick was set with a joint material of mm in between, and the erosion size of the entire lining was determined by rotational erosion. The joint material, which is inferior in corrosion resistance, is also inferior in corrosion resistance of the entire lining due to its preceding melting damage. The material of the refractory brick used for the lining is alumina in Table 1 and magnesia in Table 2.

Adhesive strength: A refractory brick was adhered with a joint material having a thickness of 2 mm, and a shear strength test was performed while hot at 1400 ° C. The materials of the refractory bricks used are alumina in Table 1 and magnesia in Table 2.

As can be seen from the test results, all of the bricks using the joint material of the present invention are excellent in workability because the construction time is short and the joint thickness is highly accurate. Further, it can be seen that the corrosion resistance and the adhesive strength are high and the durability is also excellent. Comparative Example 1 and Comparative Example 4
Is a commonly used joint mortar, which requires a long construction time and is inferior in joint accuracy. Comparative Example 2 in which short fibers were mixed was inferior in adhesive strength, and although not shown in the table, most of them were damaged by tearing during handling.

Comparative Example 3 in which a cloth and a woven fabric include sludge.
Has poor corrosion resistance and adhesive strength. Although not shown in the table, there was a further problem that mud and sludge easily dropped during handling of the jointing material.

[0033]

[Effect] When the sheet-shaped joint material of the present invention is used, it is possible to quickly and accurately carry out the construction of refractory bricks without requiring skill. This effect is extremely large under the recent shortage of workers, especially the shortage of skilled workers.

Further, the melting loss of the lining due to the stacking of refractory bricks is greatly influenced by the preceding melting loss of the joints, but the joint material of the present invention has high corrosion resistance and strength, and is also excellent in improving the durability of the lining. To be demonstrated.

[Brief description of drawings]

FIG. 1 is a schematic view showing a method for manufacturing a sheet-shaped joint material.

FIG. 2 is a schematic view showing a method for manufacturing a sheet-shaped joint material.

[Explanation of symbols]

 (1) Pressure roller (2) Sludge (3) Nonwoven fabric (4) Container

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Kazutaka Matsumoto 1 Fuji-machi, Hirohata-ku, Himeji City Nippon Steel Co., Ltd. Hirohata Works (72) Inventor Takeyoshi Ito 1-3 Niihama, Arai-cho, Takasago, Hyogo Prefecture No. 1 Harima Ceramics Co., Ltd. (72) Inventor Tatsuo Okada 1-21-2 Omachi, Hirohata-ku, Himeji City Okada Shokai Co., Ltd.

Claims (2)

[Claims] 1. A sheet-shaped joint material for refractory bricks in which a sludge comprising a refractory fine powder and a thickening agent is included in the fiber structure of a non-woven fabric. 2. A method for producing a sheet-like joint material for stacking refractory bricks, wherein a sludge comprising a refractory fine powder and a thickener is included in the fibrous structure of a non-woven fabric by the pressure action of a pressure roller. ..