WO1998021162A1 - An insulating refractory type material and a method of making such a material - Google Patents
An insulating refractory type material and a method of making such a material Download PDFInfo
- Publication number
- WO1998021162A1 WO1998021162A1 PCT/GB1997/003077 GB9703077W WO9821162A1 WO 1998021162 A1 WO1998021162 A1 WO 1998021162A1 GB 9703077 W GB9703077 W GB 9703077W WO 9821162 A1 WO9821162 A1 WO 9821162A1
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- fibres
- type material
- insulating refractory
- binder
- refractory type
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Definitions
- the present invention relates to an insulating refractory type material and a method of making such a material. More particularly, it relates to an insulating refractory type material which can be produced as a board or in more complex shaped forms from fibres which would not ordinarily withstand being used at temperatures over 1000°C, such as mineral fibres and glass fibres.
- True refractory materials are generally considered to be materials which can withstand being used to temperatures over 1000°C. They include, for example :
- Acid refractory materials such as fireclays, china clays (kaolin) , silica, flint, chalcedony, ganister and titanium dioxide;
- Neutral refractory materials such as, graphite, charcoal, coke, chromite and various carbides ;
- Basic refractory materials such as, lime, magnesia, various materials composed of alumina, dolomite and many of the rarer refractory oxides, particularly zirconia.
- Ceramics are materials made from inorganic 2 chemicals (excluding metals and alloys) by high temperature processing. These are resistant to chemical attack and include refractories, glasses, cement and cement products, vitreous enamels, abrasives, china, porcelain, clay wares and alumina.
- Refractory Ceramic Fibres can be considered to be those fibres with classification temperatures greater than 1260°C; Mineral Fibres as those having classification temperatures in the range of 500°C to 1100°C and Glass Fibres which although not generally classified by temperature would not generally be considered to have classification temperatures higher than 1000°C.
- Refractory Ceramic Fibres have, for many years, been converted into boards and more complex shaped forms through a vacuum forming process. Papers and thin boards are produced with rota forming or Foudrinier paper making machines. In all cases, the process is basically the same. Refractory ceramic fibres, binders and fillers are mixed in a slurry and the slurry is then filtered through a perforated tool, plate or belt. The filter process is driven by a differential pressure which is provided in some cases by a vacuum pump, in others by a positive pressure, and in the remainder by gravity.
- RCF's may be carcinogenic and those with fibres having a diameter below 3 ⁇ m may cause respiratory disease.
- the materials of the present invention should preferably have the following properties : They can be produced in board or more complex shaped form;
- They have dimensional stability at temperatures of up to 1260°C; and they are substantially resistant to thermal shock.
- low thermal conductivity is meant below 0.3 Wm-1 K at 500 °C, more preferably below 0.2 Wm-IK at 500°C and most preferably below 0.15 Wm-1 K at 500°C.
- a product with the desired properties can be produced using non- ceramic fibres, more particularly glass fibres or mineral fibres which fibres would be expected to soften at temperatures below 1000°C.
- the mineral fibres include diabase fibres, rockwools, and slagwools. Such fibres had not previously been used in products for use as high temperature insulating refractory - type materials. It was assumed that such fibres, particularly glass fibres, were .unsuitable because:
- an insulating refractory type material comprising a crystalline relict of a structure which comprised one or more non-ceramic fibres selected from glass fibres and mineral fibres, one or more reactive additives and a binder/ flocculation system.
- a crystalline relict obtainable from a material comprising: i) one or more non-ceramic fibres selected from glass fibres and mineral fibres, ii) one or more reactive additives, and iii) a binder/flocculation system.
- the structure may additionally have comprised an opacifier to cut radiant transmission through the material .
- the opacifier may be Titania, Rutile, Ilmenite, Zirconium Silicate, Zirconia, or any other material or mixture of materials with good radiation scattering properties. These may be present in the structure in an amount of from 5% to 50% by weight of the total weight.
- the preferred material comprises Ilmenite or Rutile in amounts of between 20% and 30% by weight of the material total weight .
- the non-ceramic fibres have been reacted with the reactive additives and binder/flocculation system, by heating to 6 above the structures devitrification point, to produce a crystalline relict.
- the crystalline forms produced in the material on firing will be determined by the starting components of the material .
- These crystalline forms include anorthite, a refractory material suitable for use up to 1250°C, which has the formulation CaAl 2 Si 2 0 2 , and mullite, a refractory material suitable for use up to 1700°C, which has the formulation 3Al 2 0 3 .2Si0 3 .
- a refractory type material comprising these crystalline forms can be produced from, for example, the following mixture.
- a refractory material including Anorthite can be produced from, for example, the following mixture.
- Cordierite is a refractory material which is suitable for use at temperatures up to 1350 °C and which has excellent thermal shock resistance due to its very low coefficient of thermal expansion.
- the coefficient of thermal expansion is about 0.0075deg " ⁇ while for Cordierite the coefficient of thermal expansion is about 0.0025 deg "1 .
- a refractory type material with Cordierite as its major crystalline relict can be produced from, for example, the following mixture.
- the crystalline forms may, .for example, include Mullite, Anorthite, Cordierite, and Celsian.
- the material of the invention may be produced for firing by the end user in service.
- a material comprising: i) one or more non-ceramic fibres selected from glass fibres and mineral fibres, ii) one or more reactive additives, and iii) a binder/flocculation system.
- the starting mixture will comprise the components in the following weight percent :
- Non-ceramic Fibres 5% - 50%
- Reactive additive 25% - 85%
- Binder/flocculation system 4% - 40% Other eg. Opacifier 0% - 50% based on the materials total weight .
- the preferred non-ceramic fibres include, for example :
- Glass fibres such as, for example, E or R type glass fibres; and Manmade mineral fibres, such as, for example, Inorphil produced by Lapinus Oy; Diabase fibres including labradorite and pyroxenes; Rockwool, such as for example, that produced by Rockwool Pic; and Slagwool , such as for example, that produced by Fibrox Inc .
- the preferred reactive additives include, for example :
- Powders based on refractory compounds including Alumina, Silica, Alumino Silicates, Magnesia, Magnesia-Alumino-Silicates, Calcium Silicates, Titania, Zirconia and Zirconium Silicate;
- the preferred binder/flocculation systems include, for example;
- Silica Sol such as, for example, those available from Nalco of Chicago Illinois or Akzo PQ Silicas of Amsterdam Netherlands. These may be mixed with starch such as, that available from Tunnel Avebe;
- Alumina Sol such as, for example that obtainable from Condea Chemie;
- Clay such as, for example, Hywhite Atlas from English China Clays.
- Aluminium Sulphate/Polymer such as, for example, polyvinyl alcohol, stabilised vinyl acetate, and acrylic copolymers .
- composition includes magnesium containing material
- crystalline forms may, for example, include Cordierite in the fired product.
- the most preferred non-ceramic fibres are glass fibres or slagwool;
- the most preferred reactive additive is an alumina, and the most preferred binder/flocculation system is a silica/starch system.
- the preferred material comprises one including the most preferred components and would typically comprise non-ceramic fibres, reactive additives and a binder/flocculation system in the following weight percents :
- Non-ceramic Fibres e.g. Glass Fibres 5% - 50%
- Reactive additive e.g. Alumina 25%- 85%
- Binder/Flocculation system e.g. Silica Sol (Dry) , and 3% - 25%
- composition ranges are :
- Non-ceramic fibres e.g. Glass Fibres 15% - 35%
- Reactive additive e.g. Alumina 50% - 70% Binder/Flocculation system e.g. Silica Sol (Dry), and 5% - 10%
- the most preferred composition comprises; Glass Fibre 26% Alumina 60% Silica Sol 8.5% Starch 5.5%
- Such a composition exhibits shrinkage of less than 1% after 24 hours soak at 1300°C and has a thermal conductivity similar to a Ceramic board.
- non-ceramic fibres contain organic material it is preferred to fire the non-ceramic fibres before mixing so as to remove the organic material present .
- the shaping tool may be planar, for the production of boards, or a more complex design for the formation of more complex forms.
- the suspension fluid usually water, (though other fluids are envisaged) may be removed by filtration and is more preferably drawn off under pressure, the preferred method being under vacuum.
- the intermediate product namely the product produced at the end of stage 4 may be fired in situ by the end user of the product.
- a material comprising:
- the fibres are preferably chopped fibres.
- the fibres Preferably have a diameter of between 3 ⁇ m and 12 ⁇ m, although larger diameters can be used, and a length of 3mm to 12mm. However, at diameters greater than 12 ⁇ m the fibre count is substantially reduced. Higher concentrations of fibre, by weight, compensate for this but diminish the refractoriness of the finished material.
- the preferred fibres are E-glass type roving or slagwool, but other types or blends of fibre can be used.
- the most preferred glass fibre is normally chopped strand fibre, but other product forms could be used.
- the reactive additive is an alumina or clay.
- Alumina has been found to give better results in terms of refractoriness and sag resistance. It can be tabular, calcined or fused.
- the reactive additive has a particle size of 40 ⁇ m or less. The optimum particle size has been found to be in the order of 5 ⁇ m. Very small particle sizes have been found to increase forming time and larger particles sizes do not disperse well, and tend to fall out of suspension.
- the binder/floceulation system is a Silica Sol/Starch system.
- Silica Sol is available in a range of concentrations, and preferably the amount of dry silica added to the finished material should be between 2% and 25% by weight of the total weight. With a higher binder content the product has been found to be stronger and has improved high temperature creep properties. A higher binder content has also been found to lead to higher thermal conductivity and lower resistance to thermal shock.
- the addition of starch at approximately 2/3 the weight of the dry silica initiates flocculation.
- Flocculation is a key part of the process. In normal mixing components are distributed randomly throughout the mixture . However when the mixture has been flocculated, the mixture clumps together, and in this case the reactive additives and the binder are attracted to the surface of the fibres. Their proximity to the fibres is critical when devitrification commences as it makes their chemical composition available to the crystals forming in the fibres.
- binder/flocculation systems can be used.
- alumina sol produces softer products, but the finely divided alumina helps to extend refractoriness.
- Clay based binders also produce softer products .
- the components can be mixed as follows :
- Mixing can be done with a single speed mixer although more preferably a dual speed mixer or two separate mixers are used.
- the first mixer is a high speed conventional or high shear mixer and is used to separate and disperse the non-ceramic fibres.
- a I D lower speed is preferably used to mix in the binder/flocculation components and to hold the flocculated mix in suspension while the product is formed.
- the slurry is then applied to the appropriate shaping tool and the water drawn off. It is then dried, preferably in a hot air batch or a continuous dryer at about 90°C to 100°C. If discolouration is to be prevented, which is not essential, the upper limit is critical. Lower temperatures can be used, but produce longer drying times .
- the product can also be dried with forced air, microwave infra-red or radio frequency drying techniques .
- the product may be machined by methods known to the man skilled in the art, such as, for example laser, water or mechanical methods.
- the end product may be fired, to about 1200°C to produce the crystalline microstructure, or the firing can be carried out in situ when the product has been put to use, such as, for example, as a refractory lining.
- Refractory type material comprising anorthite, and mullite Starting Material: E Glass Fibre 26% Tabular Alumina 60% Silica 8.5%
- Refractory type material comprising Cordierite
- compositions according to example 1 and 2 above are made by a mixing procedure substantially as follows :
- the Starch can be added before the Silica.
- the silica and the starch should not, however, be added together.
- the mixture is then ready for vacuum forming.
- CORDIERITE 3962 Major phases : (Ca,Na) (Si,Al) 4 0 a sodium calcium aluminium silicate ( anorthite ) Mg 2 Al 4 Si 5 0 18 - magnesium aluminium silicate ( cordierite ) Minor phases : MgAl 2 0 4 spinel
Abstract
Description
Claims
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU48779/97A AU4877997A (en) | 1996-11-09 | 1997-11-10 | An insulating refractory type material and a method of making such a mater ial |
EP97911368A EP0944559A1 (en) | 1996-11-09 | 1997-11-10 | An insulating refractory type material and a method of making such a material |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GB9623459A GB2319247A (en) | 1996-11-09 | 1996-11-09 | An insulating refractory type material |
GB9623459.6 | 1996-11-09 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO1998021162A1 true WO1998021162A1 (en) | 1998-05-22 |
Family
ID=10802765
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/GB1997/003077 WO1998021162A1 (en) | 1996-11-09 | 1997-11-10 | An insulating refractory type material and a method of making such a material |
Country Status (4)
Country | Link |
---|---|
EP (1) | EP0944559A1 (en) |
AU (1) | AU4877997A (en) |
GB (1) | GB2319247A (en) |
WO (1) | WO1998021162A1 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN115925430A (en) * | 2022-11-28 | 2023-04-07 | 上海宝九和耐火材料有限公司 | Wear-resistant plastic ramming mass and application thereof |
Families Citing this family (10)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB0229380D0 (en) * | 2002-12-17 | 2003-01-22 | Saffil Ltd | Mats |
GB0906837D0 (en) | 2009-04-21 | 2009-06-03 | Saffil Automotive Ltd | Mats |
US8679415B2 (en) | 2009-08-10 | 2014-03-25 | Unifrax I Llc | Variable basis weight mounting mat or pre-form and exhaust gas treatment device |
ES2615496T3 (en) | 2009-12-01 | 2017-06-07 | Unifrax Emission Control Europe Ltd. | Mounting mat |
CN106884701A (en) | 2009-12-17 | 2017-06-23 | 尤尼弗瑞克斯 I 有限责任公司 | For the installation pad of emission-control equipment |
KR20120113216A (en) | 2009-12-17 | 2012-10-12 | 유니프랙스 아이 엘엘씨 | Multilayer mounting mat for pollution control devices |
WO2011084558A1 (en) | 2009-12-17 | 2011-07-14 | Unifrax I Llc | Use of microspheres in an exhaust gas treatment device mounting mat |
US8765069B2 (en) | 2010-08-12 | 2014-07-01 | Unifrax I Llc | Exhaust gas treatment device |
US9924564B2 (en) | 2010-11-11 | 2018-03-20 | Unifrax I Llc | Heated mat and exhaust gas treatment device |
WO2012065052A2 (en) | 2010-11-11 | 2012-05-18 | Unifrax I Llc | Mounting mat and exhaust gas treatment device |
Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4307197A (en) * | 1980-05-15 | 1981-12-22 | Nalco Chemical Company | Refractory insulating veneer |
EP0338473A1 (en) * | 1988-04-18 | 1989-10-25 | Manville Corporation | Novel, high temperature resistant insulation |
US5290350A (en) * | 1990-11-28 | 1994-03-01 | Rhone-Poulenc Chimie | Insulating shaped articles comprising inorganic fibrous matrices and xanthan gum/cationic starch binders |
Family Cites Families (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPS5266511A (en) * | 1975-11-29 | 1977-06-02 | Ibigawa Electric Ind Co Ltd | Manufacture of fireeresistant heattinsulating materials |
JPS53142994A (en) * | 1977-05-20 | 1978-12-13 | Toray Ind Inc | Heat resistant sheet material |
JPS5919905B2 (en) * | 1980-03-07 | 1984-05-09 | 品川白煉瓦株式会社 | Fireproof insulation board |
JPS56160382A (en) * | 1980-05-06 | 1981-12-10 | Shinagawa Refractories Co | Fire-resistant heat-insulating board |
JPS57205380A (en) * | 1981-06-09 | 1982-12-16 | Aikoh Co | Refractory sealing material |
JPS60239371A (en) * | 1984-05-14 | 1985-11-28 | 佐藤 宏 | Heat-resistant refractory ceramics and manufacture |
DE3444397A1 (en) * | 1984-12-05 | 1986-06-05 | Didier Werke Ag | METHOD FOR PRODUCING FIRE-RESISTANT OR FIRE-RESISTANT MOLDED PARTS FROM CERAMIC FIBER MATERIAL, MOLDED PARTS PRODUCED BY THE METHOD AND THE USE THEREOF |
GB2295351B (en) * | 1994-11-25 | 1998-12-16 | Tenmat Ltd | Composite articles |
-
1996
- 1996-11-09 GB GB9623459A patent/GB2319247A/en not_active Withdrawn
-
1997
- 1997-11-10 AU AU48779/97A patent/AU4877997A/en not_active Abandoned
- 1997-11-10 WO PCT/GB1997/003077 patent/WO1998021162A1/en not_active Application Discontinuation
- 1997-11-10 EP EP97911368A patent/EP0944559A1/en not_active Withdrawn
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4307197A (en) * | 1980-05-15 | 1981-12-22 | Nalco Chemical Company | Refractory insulating veneer |
EP0338473A1 (en) * | 1988-04-18 | 1989-10-25 | Manville Corporation | Novel, high temperature resistant insulation |
US5290350A (en) * | 1990-11-28 | 1994-03-01 | Rhone-Poulenc Chimie | Insulating shaped articles comprising inorganic fibrous matrices and xanthan gum/cationic starch binders |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN115925430A (en) * | 2022-11-28 | 2023-04-07 | 上海宝九和耐火材料有限公司 | Wear-resistant plastic ramming mass and application thereof |
CN115925430B (en) * | 2022-11-28 | 2023-12-29 | 上海宝九和耐火材料有限公司 | Wear-resistant plastic ramming mass and application thereof |
Also Published As
Publication number | Publication date |
---|---|
GB9623459D0 (en) | 1997-01-08 |
AU4877997A (en) | 1998-06-03 |
GB2319247A (en) | 1998-05-20 |
EP0944559A1 (en) | 1999-09-29 |
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