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
  • C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
  • C04B26/02—Macromolecular compounds
  • C04B26/10—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
  • C04B26/12—Condensation polymers of aldehydes or ketones
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
  • B22D7/00—Casting ingots, e.g. from ferrous metals
  • B22D7/06—Ingot moulds or their manufacture
  • B22D7/10—Hot tops therefor
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
  • B22D7/00—Casting ingots, e.g. from ferrous metals
  • B22D7/06—Ingot moulds or their manufacture
  • B22D7/10—Hot tops therefor
  • B22D7/104—Hot tops therefor from exothermic material only
• • 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
  • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
  • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
  • C04B2111/00482—Coating or impregnation materials
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
  • Y02W30/00—Technologies for solid waste management
  • Y02W30/50—Reuse, recycling or recovery technologies
  • Y02W30/91—Use of waste materials as fillers for mortars or concrete

Definitions

• ABSTRACT A lining for metallurgical purposes comprises 80 90 wt.% of aluminum waste metal, 1 19 wt.% of fibrous filler, 1 10 wt.% of binding agents, such as phenoplasts or aminoplasts and up to 1 wt.% of wetting agent.
• the lining may be adapted for specialised purposes by replacing up to a quarter of the aluminum waste metal by additional constituents suited to the required purpose.
• the lining may be made by a dry process in which dry flakes of the composition are pressed to a desired shape or by a wet process in which the aluminum waste metal is added to an aqueous mixture of the fibrous filler and wetting agent whereafter the other constituents are added. Refractory, insulating and exothermic linings are described.
• plates or hollow moulded members are used for lining ingot mould hoods, mould attachments, risers, gates and the like.
• the plates or hollow moulded members are usually made from an exothermic material or an insulating material or a combination of the two, or may be laminated.
• Such plates are mainly ceramic, but it has recently been proposed to use plates and lining materials in which the main constituent is cellulosic in nature, e.g. wood chips or paper and other organic or inorganic fibrous materials.
• aluminum waste metal i.e. the solidified scum and smelting material obtained during the electrolytic manufacture or remelting of aluminum or aluminum alloys
• this substance is eminently suited for the production of linings for metallurgical purposes. It has already been proposed to use this substance in foundry practice in association with exothermic pipe eliminators, in which case use is made of the property of a limited quantity of aluminum waste metal to harden automatically when strongly heated. Hitherto, however.
• one aspect ofthe present invention provides a lining for metallurgical purposes comprising 80 90 wtf/rof aluminum waste metal.
• the binding agent is preferably one comprising a plastics, e.g. a phenoplast or aminoplast, and the composition preferably contains from 0.1 to 0.5 wt.% of the wetting agent.
• the present lining material when converted into plates and other pre-shaped moulded members, is very suitable for a variety of requirements in foundry practice, has the mechanical strength and resistance to abrasion required during heating and use, can be used in the production of small castings having a clean surface and is easy to manufacture.
• the density of the finished lining plate is relatively low, e.g. only approximately 0.8.
• the effectiveness of the present lining material with a high content of aluminum waste metal together with fibrous material and a wetting agent is due to the fact that the wetting agent apparently immunises" or passivates the waste metal, which otherwise has a violent, strongly exothermic reaction with water, so that the waste metal can safely be processed with water and does not impair the operation of plastics or similar binders, in contrast to prior-art experience.
• the present lining can contain additional constituents depending upon the required applications.
• the proportion, however, of additional constituents which may replace the main constituent of the composition should not be great enough to impair the advantageous combination of waste metal with fibrous material, the wetting agent and the binding agent. If not more than a quarter of the aluminum waste metal is replaced by additional constituents, i.e. if the total substance contains more than 60% of waste metal, the lining still has the desired properties.
• the specified composition is preferably altered by adding a thermit-like substance, such as a mixture of aluminum and iron oxide or a similar mixture comprising an oxidisable metal and an oxygen carrier such as manganese dioxide or an alkali-metal nitrate or chlorate. If such a lining is used, the extent of the exothermic effect can easily be adjusted as required by replacing a variable amount of the aluminum waste metal by the exothermic mixture, without impairing the advantageous properties of the lining.
• a thermit-like substance such as a mixture of aluminum and iron oxide or a similar mixture comprising an oxidisable metal and an oxygen carrier such as manganese dioxide or an alkali-metal nitrate or chlorate.
• the additional components replacing up to a quarter of the waste-metal content may be insulating materials such as fireclay, clay, bentonite, sand, dolomite, kieselguhr or the like.
• the lining can contain light-weight fillers such as expanded clay,'expanded corundum, vermiculite, perlite, light fireclay or the like, which can likewise replace the waste-metal content to the extent specified, thus giving very low-density linings this being particularly useful where the lining is in the form of plates.
• light-weight fillers such as expanded clay,'expanded corundum, vermiculite, perlite, light fireclay or the like, which can likewise replace the waste-metal content to the extent specified, thus giving very low-density linings this being particularly useful where the lining is in the form of plates.
• the additional components can also be used to adjust the properties of the lining material after use. After coming into contact with the melt, the lining is sintered and, after the casting and cooling process has ended, forms a cohesive member which can be taken out as a whole. Alternatively, the composition of the lining can be adjusted by admixtures so that the lining disintegrates after casting.
• the fibrous filler forming part of the composition of the present lining is preferably an inorganic fibrous filler such as asbestos, amosite, glass fibers, mineral wool or the like, asbestos fibers being particularly preferred. If required, however, the lining can also contain organic fibrous materials, such as saw-dust, rice straw or other cellulosic fibers or plastics fibers or the like, which may also be refractory.
• the solids out of which the lining is constructed are usually used in finely-divided form.
• the aluminum waste material, binder and other constituents, if present should have a particle size between very fine" and 2.5 mm., and at least half the particles should have a maximum size of 1 mm..
• the fibrous filler is mixed with the wetting agent, preferably in an aqueous preparation thereof, and more water is added if necessary, after which finely-divided aluminum waste metal is introduced into the aqueous mixture, the binder or components thereof are added and the whole is given further treatment to form a mixture which can be formed into a casting for the desired lining and dried to give the finished product.
• the mixture containing all the constituents is further processed by converting it into a pasty material, adding water if necessary, placing the pasty material on a porous or sieve-like support and shaping it by suction or pressure into castings which have sufficient green strength to be handled.
• a substantially dry method can be used, in which case the mixture of all the constituents is processed under dry conditions to form dry flakes which can immediately be pressed into castings having the desired shape.
• the wetting agents which may be used in preparing the present composition can be conventional products known in the detergent industry, provided they are suitable for the purpose of the invention.
• the following substances are examples of those which are suitable: anion-active compounds such as alkylbenzene sulfonates, alkyl sulfates and sulfonates, sulfated fatty acid esters, or non-ionisable substances such as alkoxylated fatty acid condensation products or the like, and various mixtures of these substances.
• the wetting agents are used in the form of liquid concentrates in the manufacture of the lining.
• a lining designed to have a predominantly exothermic effect, wherein up to a quarter of the content of aluminum waste metal is replaced by suitable constituents, can have substantially the following composition:
• the binding agent need not be a plastics binder but can be another substance such as petroleum pitch, dextrin, a tar product, sulfite waste liquor or the like.
• the plate was manufactured in the manner described in Example I, i.e. the asbestos fibers and the saw-dust were first treated with the wetting agent. The drying temperature however, was only 255C. and the drying was conducted for 3 hours.
• Binder phenolic resin
• Same wetting agent as in Example I l71 Finely-divided metallic aluminum 9'71 Colcothar 4 7l Cryolite 4%
• the finished lining plate was manufactured by the same method as described in Example 1, except that the constituents of the exothermic mixture were worked into the slurry between the time when the aluminum waste metal and the binder components were added.
• a lining for metallurgical purposes comprising 60 90 wt. 7: of aluminum waste metal,
• binding agent selected from the group consisting of phenoplasts and aminoplasts
• wetting agent 0.0l 1 wt. 7( of wetting agent, wherein the wetting agent is selected from the anion-active compounds and non-ionic compounds and mixtures thereof,
• additional constituents selected from the group consisting of exothermic materials, insulating materials. lightweight fillers.
• the lining of claim 1 adapted as an exothermic lining, wherein the other constituent is a mixture of aluminum and iron oxide.
• the lining of claim 1, wherein the lightweight filler is selected from expanded clay, expanded corundum, vermiculite, perlite and light fireclay.
• wetting agent is selected from alkylbenzene sulfonates, alkyl sulfates, alkyl sulfonates, sulfated fatty acid esters and alkoxylated fatty acid condensation products.
• a lining for metallurgical purposes having a predominantly exothermic effect comprising 60 80 wt. 7: of aluminum waste metal,
• wetting agent selected from anionactive and non-ionic compounds
• l 10 wt. 7 of binding agent selected from phenoplasts and aminoplasts,
• wetting agent selected from anion-active compounds and non-ionic compounds and mixtures thereof,
• additional constituent selected from the group consisting of exothermic materials, insulating materials, lightweight fillers, the method steps of providing an aqueous preparation of the fibrous filler and wetting agent, adding the aluminum waste metal in finely divided form, in the case of an exothermic mixture together with the components of the mixture, adding the binder or components reactive to form the binder, treating the resulting mixture to render it suitable for forming into the desired shape of the lining, forming the lining and drying the formed lining to harden it.
• wetting agent is selected from the group consisting of alkylbenzene sulfonates, alkyl sulfates, alkyl sulfonates, sulfated fatty acid esters and alkoxylated fatty acid condensation UNITED STATES- PATENT OFFICE CERTIFICATE OF CORRECTION Patent No. 3,878,142 Dated AP'r'i'I 1 q 1 -1::

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• Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Ceramic Engineering (AREA)
• Mechanical Engineering (AREA)
• Structural Engineering (AREA)
• Materials Engineering (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Organic Chemistry (AREA)
• Compositions Of Macromolecular Compounds (AREA)
• Road Paving Structures (AREA)
• Ceramic Products (AREA)
• Compositions Of Oxide Ceramics (AREA)
• Mold Materials And Core Materials (AREA)

Applications Claiming Priority (1)

Publications (1)

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Cited By (8)

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Citations (10)

• 0
  • BE BE791956D patent/BE791956A/xx not_active IP Right Cessation
• 1971
  • 1971-12-03 AT AT1044271A patent/ATA1044271A/de not_active Application Discontinuation
• 1972
  • 1972-11-30 IT IT3234172A patent/IT974687B/it active
  • 1972-12-01 CH CH1755172A patent/CH612104A5/xx not_active IP Right Cessation
  • 1972-12-01 DE DE19722258990 patent/DE2258990A1/de active Pending
  • 1972-12-01 NL NL7216343A patent/NL7216343A/xx not_active Application Discontinuation
  • 1972-12-01 GB GB5567872A patent/GB1405506A/en not_active Expired
  • 1972-12-01 LU LU66579D patent/LU66579A1/xx unknown
  • 1972-12-01 FR FR7242787A patent/FR2162157B1/fr not_active Expired
  • 1972-12-04 US US31186872 patent/US3878142A/en not_active Expired - Lifetime

Patent Citations (10)

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