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Lightweight dry refractory

A technology of refractory materials and lightweight filling materials, applied in the field of dry refractory materials, can solve problems such as damage to equipment, injury to personnel, time delay, etc.

Inactive Publication Date: 2002-09-18
ALLIED MINERAL PROD
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

When this occurs, molten material can burn through the enclosure, which could cause serious damage to equipment and / or personal injury
This type of burnthrough can cause unscheduled delays in the timing of repair operations on linings, steel shells and structures, and certain peripheral equipment

Method used

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Examples

Experimental program
Comparison scheme
Effect test

Embodiment 1

[0097] An insulated dry refractory composition was prepared for use in heat containment in an annular furnace for baking carbon anodes in the operation of an aluminum reduction cell. Ring furnaces typically have a series of refractory lined pipe sections and carbon anode bakeout troughs, usually 10-15 feet below ground level. The pipe wall temperature is generally about 2100-2350°F. Concrete superstructures usually include external pipe walls. A secondary lining of insulating bricks or insulating castable blocks is typically used to reduce heat loss and protect concrete from degradation due to prolonged heating. The composition is suitable for use in ring furnaces, but not for insulating fireclay bricks or insulating castable blocks.

[0098] Insulating dry refractory compositions were prepared with the following approximate particle size components, in amounts expressed in approximate volume percents:

[0099] Component Volume %

[0100] Calcined chert-like clay, -4 mesh ...

Embodiment 2

[0109] Preparation of insulated dry refractory compositions for loading molten metal / slag and containing heat in ladle tanks. Ladle tanks must be able to withstand the high temperatures of molten metal and slag and be resistant to corrosion. They must also have acceptable heat loss during tapping. Steel ladles typically have a high alumina or basic refractory working lining and a secondary refractory lining of special grade refractory bricks, castable blocks or generally dense dry vibrable refractories. The secondary lining ideally provides resistance to molten metal and slag when the working lining burns through, relieves thermal and mechanical stress on the working lining, and provides high insulation value. Because ladle tanks can be tapped at temperatures of 3050°F or higher, tapping times have been increasing, placing higher demands on refractory properties. Special grade refractory bricks and castables provide good metal and slag loading capacity, but poor stress relie...

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Abstract

A dry refractory composition having superior insulating value. The dry refractory composition also may have excellent resistance to molten metals and slags. The composition includes filler lightweight material, which may be selected from perlite, vermiculite, expanded shale, expanded fireclay, expanded alumina silica hollow spheres, bubble alumina, sintered porous alumina, alumina spinel insulating aggregate, calcium alumina insulating aggregate, expanded mulllite, cordierite, and anorthite, and matrix material, which may be selected from calcined alumina, fused alumina, sintered magnesia, fused magnesia, silica fume, fused silica, silicon carbide, boron carbide, titanium diboride, zirconium boride, boron nitride, aluminum nitride, silicon nitride, Sialon, titanium oxide, barium sulfate, zircon, a sillimanite group mineral, pyrophyllite, fireclay, carbon, and calcium fluoride. The composition also may include dense refractory aggregate, which may be selected from calcined fireclay, calcined Chamotte, a sillimanite group mineral, calcined bauxite, pyrophyllite, silica, zircon, baddeleyite, cordierite, silicon carbide, sintered alumina, fused alumina, fused silica, sintered mullite, fused mullite, fused zirconia, sintered zirconia mullite, fused zirconia mullite, sintered magnesia, fused magnesia, sintered spinel, and fused spinel refractory grog, a heat activated bonding agent, and a dust suppressant.

Description

field of invention [0001] The present invention relates to dry refractory materials (i.e. monolithic refractory materials installed in dry powder form without the addition of water or liquid chemical binders), and in particular to lightweight dry refractory materials with superior thermal insulation qualities. Background technique [0002] Refractories are used as service linings for metalworking and transport vessels containing molten metal, slag and associated heat and gases. These liners are typically expendable materials that corrode or become damaged when exposed to the conditions within the vessel. When a certain amount of wear or damage to the lining occurs, the metalworking process must be interrupted, sometimes for a considerable length, in order to repair or replace the refractory layer. The frequency with which these interruptions occur is determined by the rate at which the processing consumes the liner. The duration of these interrupted processes depends on th...

Claims

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Application Information

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Patent Type & Authority Applications(China)
IPC IPC(8): C04B35/634C04B35/66
CPCC04B35/632C04B35/63448C04B35/63496C04B35/66
Inventor D·K·多扎J·Y·刘
Owner ALLIED MINERAL PROD
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