US20050239630A1 - Powder composition for castable refractory and premixed material comprising the same, method for applying premixed material and refractory hardene product therefrom - Google Patents

Powder composition for castable refractory and premixed material comprising the same, method for applying premixed material and refractory hardene product therefrom Download PDF

Info

Publication number
US20050239630A1
US20050239630A1 US10/519,005 US51900504A US2005239630A1 US 20050239630 A1 US20050239630 A1 US 20050239630A1 US 51900504 A US51900504 A US 51900504A US 2005239630 A1 US2005239630 A1 US 2005239630A1
Authority
US
United States
Prior art keywords
hydration
premixed material
alumina cement
mass
stopper
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US10/519,005
Other languages
English (en)
Inventor
Jun Oba
Kunio Tanaka
Nobuyuki Takahashi
Takashi Fujisaki
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Taiko Refractories Co Ltd
Original Assignee
Taiko Refractories Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Taiko Refractories Co Ltd filed Critical Taiko Refractories Co Ltd
Assigned to TAIKO REFRACTORIES CO., LTD. reassignment TAIKO REFRACTORIES CO., LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: FUJISAKI, TAKASHI, OBA, JUN, TAKAHASHI, NOBUYUKI, TANAKA, KUNIO
Publication of US20050239630A1 publication Critical patent/US20050239630A1/en
Priority to US12/240,411 priority Critical patent/US8017058B2/en
Abandoned legal-status Critical Current

Links

Images

Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/62605—Treating the starting powders individually or as mixtures
    • C04B35/62645—Thermal treatment of powders or mixtures thereof other than sintering
    • C04B35/62665—Flame, plasma or melting treatment
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • C04B28/06—Aluminous cements
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/66—Monolithic refractories or refractory mortars, including those whether or not containing clay
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3205—Alkaline earth oxides or oxide forming salts thereof, e.g. beryllium oxide
    • C04B2235/3206—Magnesium oxides or oxide-forming salts thereof
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3217—Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3217—Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina
    • C04B2235/3222—Aluminates other than alumino-silicates, e.g. spinel (MgAl2O4)
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/34—Non-metal oxides, non-metal mixed oxides, or salts thereof that form the non-metal oxides upon heating, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3418—Silicon oxide, silicic acids, or oxide forming salts thereof, e.g. silica sol, fused silica, silica fume, cristobalite, quartz or flint
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/38—Non-oxide ceramic constituents or additives
    • C04B2235/3852—Nitrides, e.g. oxynitrides, carbonitrides, oxycarbonitrides, lithium nitride, magnesium nitride
    • C04B2235/3873—Silicon nitrides, e.g. silicon carbonitride, silicon oxynitride
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/42—Non metallic elements added as constituents or additives, e.g. sulfur, phosphor, selenium or tellurium
    • C04B2235/422—Carbon
    • C04B2235/424—Carbon black
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
    • C04B2235/54—Particle size related information
    • C04B2235/5418—Particle size related information expressed by the size of the particles or aggregates thereof
    • C04B2235/5427—Particle size related information expressed by the size of the particles or aggregates thereof millimeter or submillimeter sized, i.e. larger than 0,1 mm
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
    • C04B2235/54—Particle size related information
    • C04B2235/5418—Particle size related information expressed by the size of the particles or aggregates thereof
    • C04B2235/5436—Particle size related information expressed by the size of the particles or aggregates thereof micrometer sized, i.e. from 1 to 100 micron

Definitions

  • the present invention relates to a castable refractory powder composition usable for linings of vessels for molten metals such as troughs for blast furnaces, ladles, tundishes, etc., a premixed material prepared therefrom, a method for hardening the premixed material at room temperature without heating, and a hardened refractory body obtained by such a method.
  • Premixed castable refractories which are obtained by tempering castable refractory powder compositions with water or other tempering liquids in advance in other sites than casting sites, such as factories, etc., and transported to the casting sites, have recently become widely used as refractories for linings of vessels for molten metals such as troughs for blast furnaces, ladles, tundishes, etc.
  • the premixed materials suffer from new problems such as hardening with time, the separation of aggregate or water during transportation, etc., they are advantageous over conventional castable refractory materials in (a) reduced unevenness in the properties of refractory bodies obtained therefrom because of a stabilized amount of tempering water and sufficient tempering, (b) the omission of a tempering step leading to reduced labor in site and the generation of no dust, resulting in improved working environment, and (c) no hardening even if a casting operation is once stopped, because the materials are not hardened at room temperature, etc. Because of these advantages, the premixed materials have become widely used.
  • JP 4-83764 A and JP 6-48845 A disclose methods for thermally hardening premixed materials containing heat-hardening agents at a temperature of 80° C. or higher.
  • these heat-hardening methods are disadvantageous in high casting cost because of energy loss due to heat-hardening, and periodic maintenance due to the thermal deformation of molds, etc. They are also disadvantageous in the reduced strength of the resultant refractory body due to rapid water removal by heating.
  • JP 5-60469 A uses alumina cement in the form of slurry as the room-temperature-hardening binder.
  • the alumina cement slurry is hardened with time, it cannot be produced in advance, but should be prepared at the time of casting.
  • JP 2000-16843 A proposes an alumina cement composition having an extremely long working time, its gunning method and an unshaped refractory obtained by such a gunning method. It can be stored and used days after gunning without discarding a castable refractory remaining in an apparatus because of a extremely long working time. Accordingly, the gunning method using such an alumina cement composition enables the reduction of cost and working.
  • the alumina cement composition of JP 2000-16843 A comprises alumina cement prepared from a clinker having a crystalline mineral composition comprising 60 to 95% by weight of CaO.2Al 2 O 3 , 5 to 30% by weight of 2CaO.Al 2 O 3 .SiO 2 and 10% or less by weight of CaO.Al 2 O 3 , and a hardening retarder for the alumina cement.
  • a retarder at least one selected from the group consisting of phosphoric acids, a boric acid, silicofluorides, hydroxycarboxylic acids, polycarboxylic acids, polyhydroxycarboxylic acids, polyoxyalkylenes and saccharides.
  • the alumina cement clinker mineral described in this reference comprises CaO.2Al 2 O 3 and 2CaO.Al 2 O 3 .SiO 2 as main components, its hydrating activity is extremely low. Accordingly, though hardening retarders composed of alkaline salts such as sodium tripolyphosphate, sodium citrate, sodium polyacrylate, etc., which are described in Examples of this reference, exhibit an effective retarding effect on the alumina cement based on low-hydrating-activity clinker minerals, their retarding effect on common alumina cement based on high-hydrating-activity CaO.Al 2 O 3 is as insufficient as failing to reach 24 hours.
  • an object of the present invention is to provide a castable refractory powder composition containing alumina cement capable of providing a premixed material by tempering with water, which can keep flowability for a long period of time.
  • Another object of the present invention is to provide a premixed material containing alumina cement, which can keep flowability for a long period of time.
  • a further object of the present invention is to provide a method for casting such a premixed material comprising making it hardenable at room temperature at the time of casting.
  • a still further object of the present invention is to provide a hardened refractory body obtained by hardening such a premixed material at room temperature.
  • the castable refractory powder composition of the present invention comprises refractory aggregate, fine refractory powder, alumina cement, a dispersing agent and a powdery hydration stopper for the alumina cement, the hydration stopper being a material, which is acidic in a state of an aqueous solution, and the amount of the hydration stopper being controlled such that a premixed material obtained by tempering the castable refractory powder composition with water has a pH of 2 to 7.
  • the premixed material of the present invention is obtained by tempering a castable refractory powder composition comprising refractory aggregate, fine refractory powder, alumina cement, a dispersing agent and a hydration stopper for the alumina cement with water in advance, the hydration stopper being a material, which is acidic in a state of an aqueous solution, and the amount of the hydration stopper being controlled such that the premixed material has a pH of 2 to 7.
  • the method of the present invention for casting a premixed material comprises tempering a castable refractory powder composition comprising refractory aggregate, fine refractory powder, alumina cement, a dispersing agent and an alumina cement hydration stopper with water in advance to prepare the premixed material, adding an alumina cement hydration starter to the premixed material and mixing them immediately before casting, and then casting the resultant mixture into a mold.
  • a material which is acidic in a state of an aqueous solution, is used as the hydration stopper, that the amount of the hydration stopper is controlled such that the premixed material has a pH of 2 to 7, and that the amount of the hydration starter is preferably 0.02 to 0.5% by mass (outer percentage), based on the total amount (100% by mass) of the refractory aggregate, the fine refractory powder and the alumina cement.
  • the hardened refractory body of the present invention is obtained by adding an alumina cement hydration starter to the above premixed material and mixing them, and then casting the resultant mixture.
  • the hydration stopper used in the castable refractory powder composition is preferably at least one selected from the group consisting of hydroxycarboxylic acids and their salts, a polyacrylic acid and its derivatives, salts of an acrylic acid, chelating agents, condensed phosphate, aluminum phosphate and a boric acid.
  • a phosphoric acid may be used as the hydration stopper in place of the above compounds.
  • the alumina cement hydration starter added to the premixed material is preferably at least one selected from the group consisting of aluminates, hydroxides, carbonates, nitrites, silicates and borates of alkali metals, and oxides and hydroxides of alkaline earth metals.
  • the premixed material it is preferable to convey the premixed material through a pipe by the action of a pump, add the alumina cement hydration starter to the premixed material in the pipe and mix them by a line mixer connected to the pipe, and cast the resultant mixture from the outlet into the mold.
  • the storable days of the premixed material of the present invention after production are 5 days or more, preferably 7 days or more. Accordingly, there may be 5 days or more, preferably 7 days or more from the production of the premixed material to the addition of the hydration starter.
  • FIG. 1 ( a ) is a partial cross-sectional view showing one example of an apparatus for casting the premixed material of the present invention, which comprises a line mixer having an outlet at one end; and
  • FIG. 1 ( b ) is a partial cross-sectional view showing another example of an apparatus for casting the premixed material of the present invention, which comprises a line mixer and a flexible hose connected to a tip end thereof.
  • the castable refractory powder composition of the present invention comprises refractory aggregate, fine refractory powder, alumina cement, a dispersing agent and a small amount of powdery alumina cement hydration stopper.
  • the castable refractory powder composition may properly comprise thickeners, reinforcing materials, agents for preventing explosive spalling, antioxidants, etc., if necessary, in addition to the above components.
  • the premixed material of the present invention is prepared by tempering the above-described castable refractory powder composition with water to castable flowability in advance.
  • the alumina cement of JIS Class 1, 2 or 3 is preferably used in the present invention to provide the resultant cast refractories with fire resistance, corrosion resistance and high-temperature strength, etc.
  • the amount of the alumina cement depends on the type of the hydration stopper.
  • the amount of the alumina cement is preferably 0.1 to 12% by mass based on the total amount (100% by mass) of the refractory aggregate, the fine refractory powder and the alumina cement.
  • the amount of the alumina cement is more preferably 0.3 to 8% by mass.
  • the hydration stopper is a material, whose aqueous solution is acidic.
  • the hydration stopper should be powdery.
  • the powdery hydration stopper include hydroxycarboxylic acids and their salts, a polyacrylic acid and its derivatives, salts of an acrylic acid, chelating agents, condensed phosphate, aluminum phosphate and a boric acid, which may be used alone or in combination.
  • the hydration stopper needs not be in a powdery state but may be phosphoric acid usually sold in a water-containing state.
  • hydroxycarboxylic acid or its salt examples include glycolic acid, lactic acid, citric acid, sodium dihydrogen citrate, tartaric acid, malic acid, malonic acid, gluconic acid, basic aluminum lactate [for instance, “TAKICERAM GM” (trade name) containing 32% by mass of Al 2 O 3 , 45.5% by mass of lactic acid and 4.8% by mass of P 2 O 5 , available from Taki Chemical Co., Ltd.], etc. Because lactic acid and gluconic acid are liquids, they are added to the premixed material.
  • the polyacrylic acid derivatives are copolymers of an acrylic acid monomer and another monomer. Another monomer is selected from those having no adverse effect on the solubility of the polymers in water.
  • the salts of an acrylic acid may be aluminum acrylate, etc.
  • the chelating agents may be EDTA, etc.
  • Examples of the condensed phosphate include acidic sodium pyrophosphate, sodium hexametaphosphate, acidic sodium hexametaphosphate, sodium ultrapolyphosphate, etc.
  • condensed phosphate and a polyacrylic acid may also be used as a dispersing agent.
  • the amount of condensed phosphate or a polyacrylic acid added as the dispersing agent is usually about 0.05 to 0.15% by mass, too small to make the premixed material have a pH of 2 to 7.
  • the amount of sodium ultrapolyphosphate added is preferably 0.4% by mass.
  • the inventors have unexpectedly found that condensed phosphate and a polyacrylic acid acting as the dispersing agent when added in a small amount would be able to stop the hydration reaction of the alumina cement, making it possible to store the premixed material for 5 days or more, if they were added in such an increased amount as to make the premixed material have a pH of 2 to 7.
  • the amount of the acidic hydration stopper should be adjusted to make the premixed material have a pH of 2 to 7, though it may mainly depend on the acidity of the hydration stopper and the amount of the alumina cement in the castable refractory powder composition.
  • the premixed material has a pH of higher than 7, the hydration-stopping effect is too small to have high storability.
  • the premixed material has a pH of lower than 2
  • the premixed material is likely to be false setted, similarly failing to have high storability. It is presumed that considerable heat generation in this false setting phenomenon is caused by a direct chemical reaction between the alumina cement and the acid.
  • the premixed material preferably has a pH of 3 to 6.
  • the acidic hydration stopper functions according to the following mechanism.
  • the alumina cement is immediately reacted to elute Ca 2+ and Al 3+ ions.
  • the pH of water increases, and a hydrate of alumina cement starts to be deposited when the pH reaches a certain level.
  • the existence of the acidic hydration stopper captures Ca 2+ , so that the added water kept slightly acidic functions to suppress the hydration reaction of alumina cement.
  • the gelation of aluminum hydroxide one of alumina cement hydrates, occurs. This aluminum hydroxide gel is deposited on and covers a surface of the alumina cement.
  • the hydration reaction of the premixed material of the present invention containing the hydration stopper stops at least for 5 days after production, preferably for 7 days or more.
  • the storable days of the premixed material are 5 days or more, preferably 7 days or more. Accordingly, there are sufficient days from production in a factory to storing, transportation to a casting site and casting at the site.
  • refractory aggregate is at least one selected from the group consisting of electrofused alumina, sintered alumina, bauxite, kyanite, andalusite, mullite, chamotte, pyrophyllite, quartz, alumina-magnesia spinel, magnesia, zircon, zirconia, silicon carbide, graphite, pitch, etc., and two or more of them may be used in combination, if necessary.
  • Usable as the fine refractory powder is fine powder of at least one selected from the group consisting of alumina, amorphous silica, silica, titania, mullite, zirconia, chromia, silicon carbide, carbon, clay, etc.
  • the fine refractory powder preferably has an average size of 70 ⁇ m or less.
  • the use of ultrafine refractory powder as small as 10 ⁇ m or less, preferably 1 ⁇ m or less as part of the fine refractory powder provides a premixed material with good flowability even with a reduced amount of water, when used with a dispersing agent.
  • the dispersing agent include sodium hexametaphosphate, acid sodium hexametaphosphate, condensed phosphate such as sodium ultrapolyphosphate, etc., P-naphthalenesulfonate-formalin condensates, melamine sulfonate-formalin condensates, an aluminosulfate and its salts, a lignin sulfonic acid and its salts, a polyacrylic acid and its salts, and polycarboxylic acids and their salts, etc., and they may be used alone or in combination.
  • the amount of the dispersing agent is preferably 0.01 to 1% by mass (outer percentage) based on the total amount (100% by mass) of the refractory aggregate, the fine refractory powder and the alumina cement.
  • amount of the dispersing agent is less than 0.01% by mass or more than 1% by mass, it is difficult to obtain a good dispersion of the fine refractory powder.
  • all dispersing agents may not necessarily be added in the above range, the amount should be properly changed depending on the type of the dispersing agent. For instance, when condensed phosphate and a polyacrylic acid and its salts are used, their amount is usually about 0.05 to 0.15% by mass.
  • the castable refractory powder composition of the present invention may contain other components in a range (outer percentage), in which the storability of the premixed material and the function of the hydration starter are not hindered.
  • it may contain inorganic or metal fibers for improving the strength of the cast body, organic fibers or foaming agents for preventing steam explosion during drying, antioxidants such as boron carbide, etc.
  • the premixed material of the present invention may further contain thickeners such as cellulose derivatives, gums, alginates, etc., for preventing the separation of the aggregate or water during transportation.
  • the premixed material of the present invention is controlled to have castable workability by tempering the above castable refractory powder composition with water in advance, and the amount of the tempering water is an important factor to obtain a dense refractory body.
  • the density of the refractory body can be increased by uniformly tempering the castable refractory powder composition with the tempering water in such a reduced amount that the flowability is not deteriorated.
  • the amount of the tempering water is preferably about 4.5 to 9% by mass (outer percentage), and more preferably 5 to 8.5% by mass (outer percentage), based on 100% by mass of the castable refractory powder composition.
  • the amount of the tempering water is less than 4.5% by mass, the resultant premixed material has low flowability.
  • it exceeds 9% by mass the separation of the aggregate and water from the premixed material tends to occur during transportation.
  • the hydration starter is a material for recovering the stopped hydration of the alumina cement.
  • Usable as the hydration starter is at least one selected from the group consisting of aluminates, hydroxides, carbonates, nitrites, silicates and borates of alkali metals, and oxides and hydroxides of alkaline earth metals.
  • the type and amount of the hydration starter should be determined depending on the type and amount of the hydration stopper added to the premixed material.
  • the amount of the hydration starter added is preferably 0.02 to 0.5% by mass (outer percentage) based on the total amount (100% by mass) of the refractory aggregate, the fine refractory powder and the alumina cement.
  • the amount of the hydration starter is more preferably 0.04 to 0.3% by mass (outer percentage).
  • the hydration starter may be added in the form of a solution or slurry.
  • the hydration starter functions according to the following mechanism.
  • the hydration starter turns water in the premixed material alkaline because it is alkaline.
  • Alkaline water dissolves a film of an aluminum hydroxide gel covering the surface of the alumina cement, exposing an unreacted new surface of the alumina cement, thereby starting the hydration reaction of the alumina cement.
  • the method for casting the premixed material of the present invention comprises adding the alumina cement hydration starter to the premixed material and mixing them immediately before casting, and then casting the resultant mixture into a mold.
  • a means for adding the alumina cement hydration starter to the premixed material and mixing them is not restrictive, but may be a usual mixer or other means. However, it is preferable to use a line mixer as a mixing means, to make in-site mixing unnecessary as one of the advantages of the premixed material, and to save labor in a mixing step.
  • the line mixer is an apparatus having no driving means but a mechanism of disturbing a fluid flow by the energy of an entering fluid. Accordingly, the line mixer in a piping system uniformly mixes a fluid (for instance, different liquids, powder or these mixtures).
  • a fluid for instance, different liquids, powder or these mixtures.
  • Usable as the line mixer are a static mixer, a twisted pipe, combined different-size pipes, etc., and the static mixer is preferable in excellent stirring capacity.
  • the static mixer is a tubular apparatus having spiral mixing elements mounted therein, so that two or more fluids passing through the pipe can be uniformly mixed.
  • the static mixer may be called “stationary mixer.”
  • a preferred example of the static mixer is disclosed in JP 2000-356475 A.
  • Particularly preferable is a static mixer comprising 6 or more mixing elements of 40 to 150 mm in inner diameter with an axial length/inner diameter ratio of 1.5 to 3.
  • the depicted casting apparatus comprises a pipe 5 , a pump 3 disposed upstream of the pipe 5 , a hopper 4 mounted to the pump 3 , a line mixer 9 having an outlet 10 attached to the downstream end of the pipe 5 via a hydration-starter-injecting means 8 , a metering pump 6 disposed upstream of the pipe 18 connected to the hydration-starter-injecting means 8 , and a vessel 7 disposed upstream of the pump 6 for storing an aqueous solution or slurry 17 of the hydration starter.
  • the castable refractory powder composition containing a small amount of an alumina cement hydration stopper is first tempered with water to have castable workability in advance in a different site than a casting site, such as a production factory, etc.
  • the resultant premixed material 1 is stored in a plastic container bag 2 , etc., such that water is not evaporated, and transported to a casting site on demand.
  • the premixed material 1 is charged into the hopper 4 , and conveyed to the outlet 10 through the pipe 5 by the action of the pump 3 .
  • the aqueous solution or slurry 17 of the hydration starter is injected from the hydration-starter-injecting means 8 into the pipe 5 by the action of the metering pump 6 .
  • the aqueous solution or slurry 17 of the hydration starter is uniformly mixed with the premixed material 1 to form a room-temperature-hardenable premixed material 11 .
  • the room-temperature-hardenable premixed material 11 is cast from the outlet 10 into a mold 13 (in the depicted example, space between a permanent lining 12 for a molten metal and the mold 13 ).
  • the pump 3 used in the present invention is preferably a piston type or a squeeze type.
  • the hydration-starter-injecting means 8 is not particularly restricted. It may be, for instance, a so-called dry-gunning nozzle body with a ring therein uniformly having about 8 to 16 apertures or slits for introducing water, which is connected to a nozzle.
  • the metering pump 6 used for introducing the aqueous solution or slurry 17 of the hydration starter into the pipe 5 is preferably a multiple non-pulsating plunger pump or mohno (NEMO®) pump, more preferably a multiple non-pulsating plunger pump capable of conducting high-pressure injection.
  • the injection pressure of the metering pump 6 is preferably 5 kgf/cm 2 or more.
  • the position of the line mixer 9 may be properly changed.
  • part of the pipe 5 may extend between the line mixer 9 and the hydration-starter-injecting means 8 .
  • one end of the line mixer 9 serves as an outlet 10 in the example shown in FIG. 1 ( a )
  • a flexible hose 14 made of rubber, etc. may be connected to the line mixer 9 as shown in FIG. 1 ( b ) for easy handling, when a casting site is narrow and congested, or when a casting site is located at such a high position that the arrangement of the pipe is restricted.
  • Example 1 Example 2
  • Example 3 Example 4 Hydration Basic Citric Tartaric EDTA Stopper 1 Aluminum Acid Acid (0.7%) (% by mass) Lactate (0.5%) (0.2%) (1%) Hydration Sodium — — — Stopper 2 Hexameta- (% by mass) phosphate (0.3%) Amount (1) of 6.5 6.5 6.5 6.5 Tempering Water ph (2) of 5 to 6 4 4 5 to 6 Premixed Material Storable 7 ⁇ 7 ⁇ 7 ⁇ 7 ⁇ Days at 25° C. No.
  • Example 5 Example 6 Example 7 Example 8 Hydration Phosphoric Aluminum Polyacrylic Sodium Stopper 1 Acid Phosphate Acid (0.8%) Ultrapoly- (% by mass) (0.05%) (0.1%) phosphate (0.4%) Hydration — — — — Stopper 2 (% by mass) Amount (1) of 6.5 6.5 6.5 6.5 Tempering Water ph (2) of 5 4 4 4 Premixed Material Storable 7 ⁇ 7 ⁇ 7 ⁇ 7 ⁇ Days at 25° C. Comparative Comparative Comparative Comparative No.
  • Example 9 Example 1 Example 2 Example 3 Hydration Sodium Sodium Trisodium Phosphoric Stopper 1 Hexameta- Hexameta- Citrate Acid (% by mass) phosphate phosphate (0.8%) (0.15%) (0.3%) (0.1%) Hydration Boric Acid Boric Acid — — Stopper 2 (0.2%) (0.1%) (% by mass)
  • Examples 1 to 9 basic aluminum lactate (TAKICERAM GM)+sodium hexametaphosphate, citric acid, tartaric acid, a chelating agent (EDTA), phosphoric acid, aluminum phosphate, polyacrylic acid, sodium ultrapolyphosphate, or sodium hexametaphosphate+boric acid were added as a hydration stopper to the castable refractory powder composition.
  • the pH of the premixed material could be controlled within 2 to 7 on a day when they were produced. Any of these premixed materials had a storable day of 1 week or more.
  • Example Example Example Example 10 11 12 13 Premixed Material Example 2
  • Example 3 Example 4
  • Example Example Example Example 14 15 16 17 Premixed Material
  • Example 6 Example 7
  • Example 8 Example 9 Hydration Starter Type Calcium Sodium Sodium Calcium Hydroxide Silicate Silicate Hydroxide Slurry Solution Solution Slurry Concentration 10 25 25 10 (% by mass) Amount 0.5 0.5 0.5 0.5 (% by mass) Concentration 0.05 0.125 0.125 0.05 (% by mass) on Solid Basis Hardening Time 8 6 7 3 (hours) at 25° C. No.
  • Example Example Example Example 18 19 20 21 Premixed Material
  • Example 3 Example 9
  • Example 9 Example 3 Hydration Starter Type Sodium Lithium Lithium Sodium Hydroxide Carbonate Nitrite Silicate Solution Slurry Slurry Solution Concentration 25 10 10 25 (% by mass) Amount 0.5 0.5 0.5 0.5 (% by mass) Concentration 0.125 0.05 0.05 0.125 (% by mass) on Solid Basis Hardening Time 4 19 22 5 (hours) at 25° C. No.
  • the castable refractory powder composition having the formulation of Example 1 shown in Table 3 was tempered with 6.5% by mass of water in a large-vortex mixer, to produce 20 tons of a premixed material. After the resultant premixed material was stored at room temperature (about 15 to 23° C.) for 9 days, it was conveyed to a casting site in a steel works, and cast into a large trough of a blast furnace.
  • the premixed material 1 was first introduced into a hopper 4 , and conveyed under pressure through a pipe 5 by the action of a pump 3 to a hydration-starter-injecting means 8 disposed near a line mixer 9 , at which 0.19% by mass (on a solid basis, and outer percentage) of a solution of sodium aluminate (concentration: 19% by mass) was introduced into the premixed material.
  • the premixed material 1 was mixed through the line mixer 9 to obtain a room-temperature-hardenable premixed material 11 , which was cast through a nozzle 10 into a cavity between a permanent lining 12 and a mold 13 .
  • the room-temperature-hardenable premixed material 11 was cast into a separate small test mold, and hardened for about 11 hours to form a refractory body. After drying this refractory body at 110° C., its properties were measured. The results are shown in Table 6. TABLE 6 Bulk Density 2.82 Bending Strength (MPa) 1.2 Compression Strength (MPa) 8.2
  • the present invention is not restricted to such method.
  • the castable refractory powder composition may be transported to a casting site, where it is tempered with a predetermined amount of water to produce a premixed material for casting.
  • premixed material of the present invention makes it possible to add and mix a hydration starter at a casting site, there is enough castable time, resulting in easy casting operation.
  • the premixed material obtained by adding an alumina cement hydration stopper to a castable refractory powder composition containing alumina cement is not hardened for a long period of time, having an extremely long working time, it may reside in a mixer or a tank, etc., for a long period of time.
  • a necessary amount of the premixed material may be mixed with a hydration starter for alumina cement, and then cast into a mold. Accordingly, a premixed material produced in advance is not wasted, providing enough time for a casting operation.
  • the refractory body formed by the premixed material of the present invention is free from decrease in structural strength, which is caused by rapid dehydration by heating.
  • the use of a line mixer for adding the hydration starter to the premixed material and mixing them enables further saving of work.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Organic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Inorganic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Plasma & Fusion (AREA)
  • Thermal Sciences (AREA)
  • Ceramic Products (AREA)
US10/519,005 2002-06-28 2003-06-30 Powder composition for castable refractory and premixed material comprising the same, method for applying premixed material and refractory hardene product therefrom Abandoned US20050239630A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US12/240,411 US8017058B2 (en) 2002-06-28 2008-09-29 Castable refractory powder composition, premixed material prepared therefrom, method for casting premixed material, and hardened refractory body obtained therefrom

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
JP2002-190229 2002-06-28
JP2002190229 2002-06-28
PCT/JP2003/008280 WO2004002920A1 (ja) 2002-06-28 2003-06-30 キャスタブル耐火物用粉体組成物及びそれからなるプレミックス材、プレミックス材の施工方法並びにその耐火性硬化体

Related Child Applications (1)

Application Number Title Priority Date Filing Date
US12/240,411 Division US8017058B2 (en) 2002-06-28 2008-09-29 Castable refractory powder composition, premixed material prepared therefrom, method for casting premixed material, and hardened refractory body obtained therefrom

Publications (1)

Publication Number Publication Date
US20050239630A1 true US20050239630A1 (en) 2005-10-27

Family

ID=29996877

Family Applications (2)

Application Number Title Priority Date Filing Date
US10/519,005 Abandoned US20050239630A1 (en) 2002-06-28 2003-06-30 Powder composition for castable refractory and premixed material comprising the same, method for applying premixed material and refractory hardene product therefrom
US12/240,411 Expired - Fee Related US8017058B2 (en) 2002-06-28 2008-09-29 Castable refractory powder composition, premixed material prepared therefrom, method for casting premixed material, and hardened refractory body obtained therefrom

Family Applications After (1)

Application Number Title Priority Date Filing Date
US12/240,411 Expired - Fee Related US8017058B2 (en) 2002-06-28 2008-09-29 Castable refractory powder composition, premixed material prepared therefrom, method for casting premixed material, and hardened refractory body obtained therefrom

Country Status (8)

Country Link
US (2) US20050239630A1 (ja)
EP (1) EP1535887A1 (ja)
JP (1) JP4382662B2 (ja)
KR (1) KR20050034652A (ja)
CN (1) CN1308260C (ja)
AU (1) AU2003246149A1 (ja)
CA (1) CA2491530A1 (ja)
WO (1) WO2004002920A1 (ja)

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20110064841A1 (en) * 2008-09-12 2011-03-17 Nippon Oil Corporation Molding Apparatus for Modified Sulfur Concrete Substance Product
US20110251045A1 (en) * 2008-10-24 2011-10-13 Yoshitoshi Saito Binder for monolithic refractories and monolithic refractory
CN109970458A (zh) * 2017-12-28 2019-07-05 蓝星硅材料有限公司 一种改性碳质溜槽及其制备方法
EP3573941A4 (en) * 2017-01-25 2020-10-28 Stellar Materials, LLC SINGLE ADDITIVE REFRACTORY MATERIALS SUITABLE FOR MULTIPLE APPLICATION PROCESSES
US20200346279A1 (en) * 2017-11-20 2020-11-05 Kao Corporation Structure for producing cast
US11214519B2 (en) 2015-10-20 2022-01-04 Hilti Aktiengesellschaft Two-component mortar system based on aluminous cement and use thereof
US11267765B2 (en) 2017-04-07 2022-03-08 Hilti Aktiengesellschaft Use of amorphous calcium carbonate in a fire-resistant inorganic mortar system based on aluminous cement to increase load values at elevated temperatures
US11858866B2 (en) 2015-10-20 2024-01-02 Hilti Aktiengesellschaft Fire-resistant two-component mortar system based on aluminous cement for a fire-resistant chemical fastening of anchors and post-installed reinforcing bars and use thereof

Families Citing this family (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9802866B2 (en) * 2005-06-09 2017-10-31 United States Gypsum Company Light weight gypsum board
JP4528224B2 (ja) * 2005-07-29 2010-08-18 黒崎播磨株式会社 不定形耐火物の施工方法およびそれに使用するスラリー
FR2892717B1 (fr) * 2005-10-28 2008-09-05 Ecole Nationale Superieure Artes Metiers Produits cimentaires a surface gelifiee
JP2007145618A (ja) * 2005-11-25 2007-06-14 Taiheiyo Material Kk 余りモルタル又はコンクリート用固結抑制剤及び余りモルタル又はコンクリートの処理方法
JP2008007369A (ja) * 2006-06-29 2008-01-17 Jfe Refractories Corp 流し込み材の硬化促進方法およびその流し込み材
CN101397204B (zh) * 2008-10-24 2011-06-08 浙江锦诚耐火材料有限公司 一种耐酸耐碱浇注料
FR2961807B1 (fr) * 2010-06-24 2013-11-01 Lafarge Sa Procede de transport d'une composition hydraulique
US9090507B2 (en) 2013-04-18 2015-07-28 Missouri Refractories Low cement spinel stabilized silicon carbide composite material
CN103319188A (zh) * 2013-06-19 2013-09-25 宜兴兴贝耐火材料制品有限公司 抗腐蚀碳化硅耐磨可塑料
FR3035399B1 (fr) * 2015-04-24 2019-08-09 Kerneos Adjuvant pour composition de ciment ou de beton refractaire, ses utilisations, et compositions de ciment et de beton refractaire
JP6054488B1 (ja) * 2015-08-19 2016-12-27 株式会社山崎工業 セルフレベリング材スラリー供給装置及び平坦面の形成方法
CN106123602B (zh) * 2016-08-19 2018-02-27 郑州东方安彩耐火材料有限公司 耐火材料安全浇注生产系统
KR20210027460A (ko) 2018-07-06 2021-03-10 바스프 에스이 유동성 내화성 물질용 조성물
CN110746195B (zh) * 2019-08-30 2022-04-12 山东耀华特耐科技有限公司 免醒可塑料生产工艺
JP7376724B2 (ja) * 2021-04-07 2023-11-08 Ｊｆｅスチール株式会社 キャスタブル耐火物

Family Cites Families (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH0653617B2 (ja) 1990-07-24 1994-07-20 品川白煉瓦株式会社 熱硬化性樋用流し込み材
JPH0560469A (ja) 1991-08-28 1993-03-09 Kawasaki Refract Co Ltd 不定形耐火物の施工方法
JP2556418B2 (ja) 1992-07-14 1996-11-20 大光炉材株式会社 不定形耐火材
JPH06293569A (ja) * 1993-04-05 1994-10-21 Nippon Steel Corp 混練耐火物
US6409819B1 (en) * 1998-06-30 2002-06-25 International Mineral Technology Ag Alkali activated supersulphated binder
JP4023916B2 (ja) 1998-07-02 2007-12-19 電気化学工業株式会社 アルミナセメント、アルミナセメント組成物、その不定形耐火物、及びそれを用いた吹付施工方法
JP3607130B2 (ja) * 1999-08-13 2005-01-05 品川白煉瓦株式会社 不定形耐火物の流し込み施工方法およびその装置

Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20110064841A1 (en) * 2008-09-12 2011-03-17 Nippon Oil Corporation Molding Apparatus for Modified Sulfur Concrete Substance Product
US20110251045A1 (en) * 2008-10-24 2011-10-13 Yoshitoshi Saito Binder for monolithic refractories and monolithic refractory
US8673797B2 (en) * 2008-10-24 2014-03-18 Nippon Steel & Sumitomo Metal Corporation Binder for monolithic refractories and monolithic refractory
US11214519B2 (en) 2015-10-20 2022-01-04 Hilti Aktiengesellschaft Two-component mortar system based on aluminous cement and use thereof
US11858866B2 (en) 2015-10-20 2024-01-02 Hilti Aktiengesellschaft Fire-resistant two-component mortar system based on aluminous cement for a fire-resistant chemical fastening of anchors and post-installed reinforcing bars and use thereof
EP3573941A4 (en) * 2017-01-25 2020-10-28 Stellar Materials, LLC SINGLE ADDITIVE REFRACTORY MATERIALS SUITABLE FOR MULTIPLE APPLICATION PROCESSES
US11059750B2 (en) 2017-01-25 2021-07-13 Stellar Materials, Llc Single additive refractory materials suitable for multiple application methods
US11267765B2 (en) 2017-04-07 2022-03-08 Hilti Aktiengesellschaft Use of amorphous calcium carbonate in a fire-resistant inorganic mortar system based on aluminous cement to increase load values at elevated temperatures
US20200346279A1 (en) * 2017-11-20 2020-11-05 Kao Corporation Structure for producing cast
US11590560B2 (en) * 2017-11-20 2023-02-28 Kao Corporation Structure for producing cast
CN109970458A (zh) * 2017-12-28 2019-07-05 蓝星硅材料有限公司 一种改性碳质溜槽及其制备方法

Also Published As

Publication number Publication date
KR20050034652A (ko) 2005-04-14
CN1662472A (zh) 2005-08-31
AU2003246149A1 (en) 2004-01-19
US8017058B2 (en) 2011-09-13
CA2491530A1 (en) 2004-01-08
JP4382662B2 (ja) 2009-12-16
US20090032999A1 (en) 2009-02-05
WO2004002920A1 (ja) 2004-01-08
EP1535887A1 (en) 2005-06-01
CN1308260C (zh) 2007-04-04
JPWO2004002920A1 (ja) 2005-10-27

Similar Documents

Publication Publication Date Title
US8017058B2 (en) Castable refractory powder composition, premixed material prepared therefrom, method for casting premixed material, and hardened refractory body obtained therefrom
EP0709354B1 (en) Non-slumping, pumpable castable and method of applying the same
US4981731A (en) Method for gunning a refractory composition
EP0931780B1 (en) Method of wet-gunning a castable refractory composition
US7166551B2 (en) Monothilic refractory composition
AU728446B2 (en) Cement-free refractory castable system for wet process pumping/spraying
JP3765522B2 (ja) 緻密質不定形耐火組成物の乾式吹付け施工方法
US5869145A (en) Wet-gunning method for dense castable refractory composition
JP4338193B2 (ja) プレミックス材の湿式吹付け施工方法
JP2972179B1 (ja) 湿式吹付用不定形耐火組成物
EP1502905A1 (en) Monothilic refractory composition
EP0798279B1 (en) Wet-gunning method
US5945168A (en) Set modifying admixtures for refractory shotcreting
JP2003073174A (ja) 湿式吹付け施工用不定形耐火物およびそれを使用した湿式吹付け施工方法
JP2965957B1 (ja) 湿式吹付用不定形耐火組成物
JPS63162579A (ja) 熱硬性不定形耐火物
JP3790622B2 (ja) 耐火物吹付け施工方法およびこの方法に使用する吹付材
JP2001002477A (ja) 湿式吹付け施工方法およびこの方法に使用する吹付材
JP2002048481A (ja) 不定形耐火物の湿式吹付け施工方法
JP2003254672A (ja) 耐食性に優れた不定形耐火物の吹付け施工方法
JPH11159970A (ja) 耐火物吹付け施工方法
Gupta Study and Preparation of High Alumina Insulating Castables
Poddar Emerging Trend Of Bond Systems In Monolithic Refractories

Legal Events

Date Code Title Description
AS Assignment

Owner name: TAIKO REFRACTORIES CO., LTD., JAPAN

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:OBA, JUN;TANAKA, KUNIO;TAKAHASHI, NOBUYUKI;AND OTHERS;REEL/FRAME:016739/0483

Effective date: 20041220

STCB Information on status: application discontinuation

Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION