TWI450872B - 高氧化鋯濃度耐火產品 - Google Patents
高氧化鋯濃度耐火產品 Download PDFInfo
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- TWI450872B TWI450872B TW098120182A TW98120182A TWI450872B TW I450872 B TWI450872 B TW I450872B TW 098120182 A TW098120182 A TW 098120182A TW 98120182 A TW98120182 A TW 98120182A TW I450872 B TWI450872 B TW I450872B
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- molten
- refractory product
- cast refractory
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- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 title description 44
- 239000000126 substance Substances 0.000 claims description 22
- 229910018072 Al 2 O 3 Inorganic materials 0.000 claims description 21
- 239000011521 glass Substances 0.000 claims description 19
- 238000000034 method Methods 0.000 claims description 12
- 229910010413 TiO 2 Inorganic materials 0.000 claims description 11
- 238000002844 melting Methods 0.000 claims description 11
- 230000008018 melting Effects 0.000 claims description 11
- 239000000203 mixture Substances 0.000 claims description 10
- 239000000463 material Substances 0.000 claims description 8
- 238000001816 cooling Methods 0.000 claims description 7
- 239000000155 melt Substances 0.000 claims description 7
- 229910052760 oxygen Inorganic materials 0.000 claims description 7
- 230000001590 oxidative effect Effects 0.000 claims description 6
- 230000008569 process Effects 0.000 claims description 6
- 238000010891 electric arc Methods 0.000 claims description 5
- 239000006060 molten glass Substances 0.000 claims description 4
- 230000009471 action Effects 0.000 claims description 3
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 3
- 239000001301 oxygen Substances 0.000 claims description 3
- 239000007789 gas Substances 0.000 claims description 2
- 230000009970 fire resistant effect Effects 0.000 claims 1
- 239000000047 product Substances 0.000 description 61
- 239000011734 sodium Substances 0.000 description 30
- CPLXHLVBOLITMK-UHFFFAOYSA-N Magnesium oxide Chemical compound [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 20
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical compound [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 description 20
- ODINCKMPIJJUCX-UHFFFAOYSA-N calcium oxide Inorganic materials [Ca]=O ODINCKMPIJJUCX-UHFFFAOYSA-N 0.000 description 12
- XEEYBQQBJWHFJM-UHFFFAOYSA-N iron Substances [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 12
- 229910004298 SiO 2 Inorganic materials 0.000 description 11
- 239000000395 magnesium oxide Substances 0.000 description 11
- 239000000292 calcium oxide Substances 0.000 description 10
- 239000012535 impurity Substances 0.000 description 10
- 239000011787 zinc oxide Substances 0.000 description 10
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 9
- IATRAKWUXMZMIY-UHFFFAOYSA-N strontium oxide Inorganic materials [O-2].[Sr+2] IATRAKWUXMZMIY-UHFFFAOYSA-N 0.000 description 9
- 238000012360 testing method Methods 0.000 description 7
- 230000015572 biosynthetic process Effects 0.000 description 6
- 229910052810 boron oxide Inorganic materials 0.000 description 6
- JKWMSGQKBLHBQQ-UHFFFAOYSA-N diboron trioxide Chemical compound O=BOB=O JKWMSGQKBLHBQQ-UHFFFAOYSA-N 0.000 description 6
- 238000004519 manufacturing process Methods 0.000 description 6
- 229910052902 vermiculite Inorganic materials 0.000 description 6
- 239000010455 vermiculite Substances 0.000 description 6
- 235000019354 vermiculite Nutrition 0.000 description 6
- 230000009466 transformation Effects 0.000 description 5
- QVQLCTNNEUAWMS-UHFFFAOYSA-N barium oxide Inorganic materials [Ba]=O QVQLCTNNEUAWMS-UHFFFAOYSA-N 0.000 description 4
- 229910000420 cerium oxide Inorganic materials 0.000 description 4
- BMMGVYCKOGBVEV-UHFFFAOYSA-N oxo(oxoceriooxy)cerium Chemical compound [Ce]=O.O=[Ce]=O BMMGVYCKOGBVEV-UHFFFAOYSA-N 0.000 description 4
- 229910052708 sodium Inorganic materials 0.000 description 4
- 229910052845 zircon Inorganic materials 0.000 description 4
- 230000008859 change Effects 0.000 description 3
- 230000007797 corrosion Effects 0.000 description 3
- 238000005260 corrosion Methods 0.000 description 3
- 238000005336 cracking Methods 0.000 description 3
- 230000001627 detrimental effect Effects 0.000 description 3
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N iron oxide Inorganic materials [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 3
- 239000002994 raw material Substances 0.000 description 3
- KKCBUQHMOMHUOY-UHFFFAOYSA-N sodium oxide Chemical compound [O-2].[Na+].[Na+] KKCBUQHMOMHUOY-UHFFFAOYSA-N 0.000 description 3
- GFQYVLUOOAAOGM-UHFFFAOYSA-N zirconium(iv) silicate Chemical compound [Zr+4].[O-][Si]([O-])([O-])[O-] GFQYVLUOOAAOGM-UHFFFAOYSA-N 0.000 description 3
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical class [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 description 2
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 2
- 238000007792 addition Methods 0.000 description 2
- 229910000272 alkali metal oxide Inorganic materials 0.000 description 2
- 238000004458 analytical method Methods 0.000 description 2
- 238000005452 bending Methods 0.000 description 2
- 229910052796 boron Inorganic materials 0.000 description 2
- 239000011449 brick Substances 0.000 description 2
- BRPQOXSCLDDYGP-UHFFFAOYSA-N calcium oxide Chemical compound [O-2].[Ca+2] BRPQOXSCLDDYGP-UHFFFAOYSA-N 0.000 description 2
- 229910002090 carbon oxide Inorganic materials 0.000 description 2
- 230000007547 defect Effects 0.000 description 2
- 238000004043 dyeing Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 239000012467 final product Substances 0.000 description 2
- 229910052742 iron Inorganic materials 0.000 description 2
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 150000001247 metal acetylides Chemical class 0.000 description 2
- 238000002156 mixing Methods 0.000 description 2
- 150000004767 nitrides Chemical class 0.000 description 2
- 239000002245 particle Substances 0.000 description 2
- 230000009467 reduction Effects 0.000 description 2
- 229910001948 sodium oxide Inorganic materials 0.000 description 2
- OGIDPMRJRNCKJF-UHFFFAOYSA-N titanium oxide Inorganic materials [Ti]=O OGIDPMRJRNCKJF-UHFFFAOYSA-N 0.000 description 2
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 1
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 1
- 229910002651 NO3 Inorganic materials 0.000 description 1
- NHNBFGGVMKEFGY-UHFFFAOYSA-N Nitrate Chemical compound [O-][N+]([O-])=O NHNBFGGVMKEFGY-UHFFFAOYSA-N 0.000 description 1
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- 238000013019 agitation Methods 0.000 description 1
- 238000005266 casting Methods 0.000 description 1
- 229910052729 chemical element Inorganic materials 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- UOUJSJZBMCDAEU-UHFFFAOYSA-N chromium(3+);oxygen(2-) Chemical class [O-2].[O-2].[O-2].[Cr+3].[Cr+3] UOUJSJZBMCDAEU-UHFFFAOYSA-N 0.000 description 1
- 230000000295 complement effect Effects 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- RKTYLMNFRDHKIL-UHFFFAOYSA-N copper;5,10,15,20-tetraphenylporphyrin-22,24-diide Chemical compound [Cu+2].C1=CC(C(=C2C=CC([N-]2)=C(C=2C=CC=CC=2)C=2C=CC(N=2)=C(C=2C=CC=CC=2)C2=CC=C3[N-]2)C=2C=CC=CC=2)=NC1=C3C1=CC=CC=C1 RKTYLMNFRDHKIL-UHFFFAOYSA-N 0.000 description 1
- 229910052593 corundum Inorganic materials 0.000 description 1
- 239000013078 crystal Substances 0.000 description 1
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 description 1
- 238000011038 discontinuous diafiltration by volume reduction Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000004615 ingredient Substances 0.000 description 1
- 230000000977 initiatory effect Effects 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 238000010309 melting process Methods 0.000 description 1
- 239000012768 molten material Substances 0.000 description 1
- 229910052863 mullite Inorganic materials 0.000 description 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
- -1 oxynitrides Chemical class 0.000 description 1
- 150000002978 peroxides Chemical class 0.000 description 1
- 229910001392 phosphorus oxide Inorganic materials 0.000 description 1
- 229910001950 potassium oxide Inorganic materials 0.000 description 1
- 239000002243 precursor Substances 0.000 description 1
- 238000010405 reoxidation reaction Methods 0.000 description 1
- 230000002441 reversible effect Effects 0.000 description 1
- 230000035945 sensitivity Effects 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000007858 starting material Substances 0.000 description 1
- VSAISIQCTGDGPU-UHFFFAOYSA-N tetraphosphorus hexaoxide Chemical compound O1P(O2)OP3OP1OP2O3 VSAISIQCTGDGPU-UHFFFAOYSA-N 0.000 description 1
- 229910052719 titanium Inorganic materials 0.000 description 1
- 239000010936 titanium Substances 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
- 229910052720 vanadium Inorganic materials 0.000 description 1
- GPPXJZIENCGNKB-UHFFFAOYSA-N vanadium Chemical compound [V]#[V] GPPXJZIENCGNKB-UHFFFAOYSA-N 0.000 description 1
- 229910001845 yogo sapphire Inorganic materials 0.000 description 1
Classifications
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- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
- C03B5/00—Melting in furnaces; Furnaces so far as specially adapted for glass manufacture
- C03B5/16—Special features of the melting process; Auxiliary means specially adapted for glass-melting furnaces
- C03B5/42—Details of construction of furnace walls, e.g. to prevent corrosion; Use of materials for furnace walls
- C03B5/43—Use of materials for furnace walls, e.g. fire-bricks
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/48—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on zirconium or hafnium oxides, zirconates, zircon or hafnates
- C04B35/484—Refractories by fusion casting
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- 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
- C04B2235/3201—Alkali metal oxides or oxide-forming salts thereof
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- 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
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- 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
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- 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
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- 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
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- 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
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- C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/3231—Refractory metal oxides, their mixed metal oxides, or oxide-forming salts thereof
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- 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
- C04B2235/327—Iron group oxides, their mixed metal oxides, or oxide-forming salts thereof
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- 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
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
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- 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
- C04B2235/3409—Boron oxide, borates, boric acids, or oxide forming salts thereof, e.g. borax
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- 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
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- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/44—Metal salt constituents or additives chosen for the nature of the anions, e.g. hydrides or acetylacetonate
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
- C04B2235/96—Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
- C04B2235/9669—Resistance against chemicals, e.g. against molten glass or molten salts
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- Ceramic Engineering (AREA)
- Materials Engineering (AREA)
- Organic Chemistry (AREA)
- Composite Materials (AREA)
- Manufacturing & Machinery (AREA)
- Structural Engineering (AREA)
- Compositions Of Oxide Ceramics (AREA)
- Furnace Housings, Linings, Walls, And Ceilings (AREA)
- Glass Compositions (AREA)
Description
本發明係關於一種具有高氧化鋯濃度之新穎熔融及澆鑄之耐火產品。
在耐火產品中,已知熔融及澆鑄產品係用於製造玻璃熔爐及燒結製品。
與燒結製品相反,熔融及澆鑄產品更常經歷結合結晶顆粒之晶粒間玻璃相。由燒結製品以及熔融及澆鑄產品引起之問題及用於解決此等問題之技術方法一般各不相同。因此,發展用於製造燒結製品之組合物並不一定適用於製造熔融及澆鑄產品,反之亦然。
熔融及澆鑄產品(常稱為電熔)係經由在電弧爐中熔化適宜原料之混合物或經由適於此類產品之任何其他技術而獲得。然後將熔料倒入模型中,得到之產品隨後進行控制冷卻循環,以達成冷卻該產品至室溫而不引起任何破裂之目的。擅長此項技術之專業人員稱該工藝為「退火」。
在熔融及澆鑄產品中,已知具有高濃度氧化鋯(亦即其包含超過85%氧化鋯(ZrO2
))之電熔產品具有抗腐蝕能力,且無任何玻璃染色及不產生任何缺陷。
通常,具有高濃度氧化鋯之熔融及澆鑄產品亦包括氧化鈉(Na2
O),以免產品中之氧化鋯及矽石形成鋯石。鋯石之形成為不利,因為其造成體積減少達20%,產生引起開裂之某些機械限制。
由des Produits生產及銷售且屬於專利案EP-B-403 387範圍之產品ER-1195當前已廣泛應用於玻璃熔爐中。該產品之化學成分按重量計算為約94%氧化鋯、4或5%矽石、約1%礬土、0.3%氧化鈉及低於0.05% P2
O5
。該組合物為應用於玻璃熔爐中之典型高濃度氧化鋯產品。
FR 2 701 022揭露具有高氧化鋯濃度之熔融及澆鑄產品,其包含(按重量計)7.0至11.2%SiO2
、0.05至1% P2
O5
、0.05至1.0%氧化硼B2
O3
及0.01至0.12% Na2
O+K2
O。
FR 2 723 583敍述具有高氧化鋯濃度之熔融及澆鑄產品,其包含(按重量計)3至8% SiO2
、0.1至2% Al2
O3
、0.05至3%氧化硼B2
O3
及0.05至3%BaO+SrO+MgO、0.05至0.6% Na2
O+K2
O及低於0.3% Fe2
O3
+TiO2
。
材料受到壓力(壓縮、張力或彎曲)下之蠕變可定義為該材料本身以黏塑性方式(亦即,以永久性方式承受該負載力之影響)變形之能力。
當前高品質玻璃之發展已提高有關用於玻璃熔爐之耐火產品之條件要求。特定言之,需要一種具有改良之蠕變性質與/或抗熱變化性之耐火產品,或更一般而言,需要一種更能在此兩種性質之間取得平衡之產品。
本發明之目的可滿足該需要。
根據第一項主要實施例,本發明提供一種熔融及澆鑄耐火產品,其包含(基於氧化物之重量百分比及合計100%):
- ZrO2
+HfO2
:補充至100%
- SiO2
:3.5%至6.0%
- Al2
O3
:0.7%至1.5%
- Na2
O+K2
O:0.10%至0.43%
- B2
O3
:0.05%至0.80%
- CaO+SrO+MgO+ZnO:<0.4%
- P2
O5
:<0.05%
- Fe2
O3
+TiO2
:<0.55%
-其他物質:<1.5%,
Al2
O3
/(Na2
O+K2
O)重量百分比之比例(A/N)大於或等於3.5及B2
O3
/(Na2
O+K2
O)重量百分比之比例(B/N)介於0.3及2.5之間。
由下文驚訝地發現,根據本發明生產之耐火產品呈現出色的蠕變性,同時維持其抗熱變化性。
有利地,此等蠕變性(尤其針對形成玻璃熔爐之熔化槽槽壁之磚塊)可以配合其尺寸,同時不會在啟動此等玻璃熔爐期間(在壓力下增加溫度)產生開裂。
有利地,提高抗熱變化性所製造之玻璃熔爐儘管因停爐引起熱變化,仍可長時間保持穩定尺寸。
根據本發明之一項實施例生產之一種耐火產品亦可包含一種或若干種以下視需要選擇之特性,但此等視需要選擇之特性需根據以下敍述之特定生產方法產生且此等視需要選擇之特性不會與上述特定生產方法無法相容。
- ZrO2
+HfO2
之重量百分比小於95.65%、或小於95.4%、或小於95.3%、或小於95.2%、或小於95.0%或小於94.5%及/或大於90.4%、或大於91.0%、或大於92.0%、或大於93.0%或大於94.0%。
-礬土Al2
O3
之重量百分比等於或小於1.4%,或等於或小於1.3%。
-礬土Al2
O3
之重量百分比大於或等於0.8%,或大於或等於1.0%或大於或等於1.1%。
- B2
O3
/(Na2
O+K2
O)重量百分比之比例(B/N)大於0.35、大於0.4、大於0.5、大於0.6、大於0.8、大於0.9、大於1.0,及/或小於或等於2.2、小於2.0、小於1.7或小於1.5。
- Al2
O3
/(Na2
O+K2
O)重量百分比之比例(A/N)大於4,較佳係大於5或大於6及/或小於10,或小於8,或小於7.5。-及/或,或,
-,或,或及/或,,或。
-氧化鉀K2
O僅作為雜質而存在,其重量百分比小於0.2%或小於0.1%。
-「其他物質」之總重量百分比小於1.0%、小於0.6%、小於0.5%或小於0.3%。
-氧化鐵及/或氧化鈦及/或氧化鈣及/或氧化鍶及/或氧化鎂及/或氧化鋅及/或氧化磷僅作為雜質而存在。
-氧化鈣及/或氧化鍶及/或氧化鎂及/或氧化鋅CaO+SrO+MgO+ZnO之總重量百分比小於0.3%,較佳係小於0.2%。
-氧化鐵及/或氧化鈦Fe2
O3
+TiO2
之重量百分比小於0.4%,較佳係小於0.3%,較佳係小於0.2%。
-「其他物質」僅由雜質組成。
-「其他物質」(無論其組成)之重量百分比總為小於0.4%,或小於0.3%,較佳係小於0.2%。
根據第一項較佳實施例,本發明提供一種熔融及澆鑄之耐火產品,其包含(基於氧化物之重量百分比及合計100%):
-ZrO2
+HfO2
:補充至100%
-SiO2
:3.5%至6.0%
-Al2
O3
:0.7%至1.5%
-Na2
O+K2
O 0.10%至0.40%
-B2
O3
:0.05%至0.80%
-CaO+SrO+MgO+ZnO:<0.4%
-P2
O5
:<0.05%
-Fe2
O3
+TiO2
:<0.55%
-其他物質:<1.5%
B2
O3
/(Na2
O+K2
O)重量百分比之比例(B/N)大於0.3、較佳係大於0.35、較佳係大於0.4、較佳係大於0.5、或大於0.8、或大於1.0,及小於2.5、小於2.2、小於2.0或小於1.5,及Al2
O3
/(Na2
O+K2
O)重量百分比之比例(A/N)大於3.5、較佳係大於4、或大於5、或大於6,及小於15、小於12、小於10、小於8或小於7.5。
具體而言,及/或。
根據第二項特定實施例,本發明提供一種熔融及澆鑄之耐火產品,其包含(基於氧化物之重量百分比及合計100%):
- ZrO2
+HfO2
:補充至100%
- SiO2
:3.5%至6.0%
- Al2
O3
:0.7%至1.5%
- Na2
O+K2
O:0.10%至0.43%
- B2
O3
:0.05%至0.60%
- CaO+SrO+MgO+ZnO:<0.4%
- P2
O5
:<0.05%
- Fe2
O3
+TiO2
:<0.55%
- 其他物質:<1.5%,
B2
O3
/(Na2
O+K2
O)重量百分比之比例(B/N)大於0.3、較佳係大於0.35、較佳係大於0.4、較佳係大於0.5、或大於0.8、或大於1.0,及小於2.5、小於2.2、小於2.0或小於1.5,及Al2
O3
/(Na2
O+K2
O)重量百分比之比例(A/N)大於3.5、較佳係大於4、或大於5、大於6,及小於15、小於12、小於10、小於8或小於7.5。
較佳地,B2
O3
組成之重量百分比大於或等於0.10%,或大於或等於0.12%,或大於或等於0.15%,及小於或等於0.50%,小於或等於0.40%或小於或等於0.30%。
根據第三項特定實施例,本發明提供一種熔融及澆鑄耐火產品,其包含(基於氧化物之重量百分比及合計100%):
- ZrO2
+HfO2
:補充至100%
- SiO2
:3.5%至6.0%
- Al2
O3
:1.1%至1.5%
- Na2
O+K2
O:0.10%至0.43%
- B2
O3
:0.05%至0.80%
- CaO+SrO+MgO+ZnO:<0.4%
- P2
O5
:<0.05%
- Fe2
O3
+TiO2
:<0.55%
-其他物質:<1.5%,
Al2
O3
/(Na2
O+K2
O)重量百分比之比例(A/N)大於3.5、較佳係大於4、或大於5、或大於6,及小於15、小於12、小於10、小於8或小於7.5,及B2
O3
/(Na2
O+K2
O)重量百分比之比例(B/N)大於0.3、較佳係大於0.35、較佳係大於0.4、較佳係大於0.5、或大於0.8、或大於1.0,及小於2.5、小於2.2、小於2.0或小於1.5,及在某些實施例中,,較佳係,或甚至。
根據第四項特定實施例,本發明提供一種熔融及澆鑄之耐火產品,其包含(基於氧化物之重量百分比及合計100%):
-ZrO2
+HfO2
:補充至100%
-SiO2
:3.5%至6.0%
- Al2
O3
:1.1%至1.5%
- Na2
O+K2
O:0.10%至0.40%
- B2
O3
:0.10%至0.40%
- CaO+SrO+MgO+ZnO:<0.4%
- P2
O5
:<0.05%
- Fe2
O3
+TiO2
:<0.55%
-其他物質:<1.5%,
B2
O3
/(Na2
O+K2
O)重量百分比之比例介於0.3及2.5之間,較佳係介於0.4及2.2之間。
在一項實施例中,及/或(Na2
O+K2
O)。
在一項實施例中,及/或。
根據第二項特定實施例,本發明提供一種熔融及澆鑄之耐火產品,其包含(基於氧化物之重量百分比及合計100%):
- ZrO2
+HfO2
:補充至100%
- SiO2
:3.5%至6.0%
- Al2O3:1.1%至1.5%
- Na2
O+K2
O:0.10%至0.43%
- B2
O3
:0.05%至0.80%
- CaO+SrO+MgO+ZnO:<0.4%
- P2
O5
:<0.05%
- Fe2
O3
+TiO2
:<0.55%
-其他物質;<1.5%,
B2
O3
/(Na2
O+K2
O)重量百分比之比例介於0.3及2.5之間,較佳係介於0.4及2.2之間。
在一項特定實施例中,。
根據本發明第一項較佳實施例生產之產品特性(必要特性或視需要選擇的特性)亦可應用於根據第二項特定實施例生產之產品,只要此等特性可與該產品相容。
最後,本發明係關於一種製造根據本發明耐火產品之製程,其包括以下連續階段:
a)混合原料,以獲得初始進料,
b)熔化該初始進料,直至得到熔料,
c)澆鑄和利用冷卻法凝固該熔料,以獲得耐火產品,
該製程之重點在於選擇該原料之方式應使最終耐火產品屬於本發明範圍內。
較佳地,必需含有最低必要濃度之氧化物(具體為Na2
O、Al2
O3
及B2
O3
),或此等氧化物之前驅物係有系統地且有方法地添加。較佳地,應一併考慮一般視為雜質之其他氧化物源內之此等氧化物濃度。
較佳地,控制冷卻階段,較佳係依每小時小於20℃、較佳係每小時約10℃之速率進行。
本發明亦關於一種特別在計畫與熔融玻璃接觸之區域中包含根據本發明耐火產品或遵循根據本發明製程製造或可能製造之耐火產品之玻璃熔爐。在根據本發明製造之熔爐中,該耐火產品可有利地作為熔融玻璃(更具體為用於電熔融)之預備槽之一部分,其中其可能與溫度超過1200℃之熔融玻璃接觸。
氧化物之重量百分比係與每一對應化學元素之總濃度相關,其以對業界標準為最穩定之氧化物形式表示;其中包括任何低氧化物,可能為氮化物、碳化物、碳氧化物、碳氮化物或甚至為上述元素之金屬類物質。
"熔料"意指為保留其形式而必須容納於容器中之液體物質。該熔料可包含一些固體顆粒,但其含量必需不足以在物質中造成任何結構。
「雜質」意指任何不可避免的成分,其係被動且必需與原料一起引入者或由於此等成分之間反應所造成之結果。雜質為非必要成分,但僅為容許成分。例如:屬於鐵、鈦、釩與鉻之氧化物、氮化物、氧氮化物、碳化物、碳氧化物及金屬類物質之化合物為雜質。
除非另有說明,否則所描述及主張之產品中所包含之全部氧化物係基於氧化物之重量百分比表示。
在根據本發明之熔融及澆鑄產品中,高濃度氧化鋯可符合高度抗腐蝕性之要求,而不使玻璃產品染色,也不會產生對玻璃品質不利之缺陷。
存在於根據本發明產品中之氧化鉿HfO2
係天然存在於氧化鋯來源之氧化鉿。因此其在根據本發明產品中之濃度小於或等於5%,一般係小於或等於2%。
矽石SiO2
之存在尤其可形成晶粒間玻璃相,在氧化鋯以有效方式進行可逆性同素異形轉型期間,換言之在自單斜晶相轉換至四角形相期間,該玻璃相容易適應氧化鋯體積變化。矽石之重量百分比應大於3.5%。另一方面,添加之矽石不應超過6.0%,因為此添加量對氧化鋯含量不利及可因此減少耐腐蝕性。
礬土Al2
O3
之存在對於形成穩定的玻璃相及對於初始進料入模型中之適當可鑄性尤其必要。其亦有助於獲得極佳之抗熱變化性。然而,氧化鋁之添加量不應超過1.5%,因為較高重量百分比可能引起玻璃相(形成富鋁紅柱石晶體)之不穩定性,尤其在氧化硼存在下時。
重量百分比大於0.10%之Na2
O+K2
O之存在有助於提高抗熱變化性程度。Na2
O之重量百分比不超過0.30%較佳,以提高蠕變容量。在根據本發明之產品中,Na2
O及K2
O氧化物視為具有類似效果。
重量百分比大於0.05%之B2
O3
之存在顯著地提高蠕變容量。然而,B2
O3
的數量應保持在可使B2
O3
/(Na2
O+K2
O)之比例小於或等於2.5,較佳係小於或等於2.2。氧化硼確實具有不利影響,因為其促進產品中形成鋯石。超過0.30%,抗熱變化性會降低。然而,重量百分比達0.80%之B2
O3
仍可接受。
根據本發明,Fe2
O3
+TiO2
之重量百分比小於0.55%及P2
O5
之重量百分比為小於0.05%。確實,已知此等氧化物有害且其含量應限於原料中所發現之微量雜質量。
「其他物質」為以上未列出之物質,換言之為彼等非ZrO2
、HfO2
、SiO2
、Al2
O3
、Na2
O、K2
O、B2
O3
、CaO、SrO、MgO、ZnO、P2
O5
、Fe2
O3
及TiO2
者。在一項實施例中,該等其他物質限於未明確需要其存在及其一般呈雜質出現於原料中者。
在另一項實施例中,該等”其他物質”可同樣包括一些適宜其存在之物質。例如,在一項實施例中,該產品有利地包含至少0.05%氧化鋇BaO。該氧化物可為雜質或若必要時,可自行添加入初始進料中。其基於氧化物之重量百分比濃度較佳為小於0.5%。
根據本發明之產品傳統上係經由以下步驟a)至c)製造:
a)混合原料,以獲得初始進料,
b)熔化該初始進料,直至獲得熔料,
c)利用冷卻法凝固該熔料,以某種方式獲得根據本發明之耐火產品。
在步驟a)中,選擇原料之方式應保證成品中之氧化物含量。
在步驟b)中,該熔化法較佳係由足夠長之電弧之共同作用進行,不會產生任何還原,並且在有利於產品再次氧化下攪拌。
為了使具有金屬態之結節形成降至最低及避免在最終產品中形成開裂或裂縫,較佳係在氧化條件下進行熔化。
較佳地,採用法國專利案n° 1208 577及其附加案n°75893及82310中敍述之長弧熔化法。
該製法包括使用電弧爐,其中電弧在進料及由該進料分隔之至少一個電極之間流動,以調整該電弧長度,從而使其還原作用降至最低,同時維持熔池上方之氧化氛圍,並藉由電弧本身的作用或藉由在熔池中通入氧化氣體(例如空氣或氧氣)或向熔池中添加氧氣釋放物質(如:過氧化物或硝酸鹽)來攪拌該熔池。
在步驟c)中,冷卻法較佳係以小於每小時20℃之速度進行,以約每小時10℃之速度進行較佳。
可使用常用於製造計畫用於玻璃熔爐之基於氧化鋯之熔融產品之任何方法,但其限制條件為需使初始進料組合物得到含有如本發明產品之組合物之產品。
以下非限制性實例係供說明本發明。
在此等實例中,使用以下原料:
-主要包含(加權平均)98.5% ZrO2
+HfO2
、0.2% SiO2
及0.02% Na2
O之氧化鋯,-含有33%矽石之鋯石,-由Pechiney銷售並包含平均99.4%礬土Al2
O3
之AC44型礬土,-純度大於99%之硼與鈉之氧化物。
依據一般電弧爐製法製備之產品係經過熔化然後澆鑄,以獲得220mm×450mm×150mm磚塊。
最終產品之化學分析列於表1;其為以重量百分比形式出示之平均化學分析。
在稱為「非等溫的」蠕變試驗中,採用有4個壓力點之彎曲試驗組態(外部壓力點之間距離L=125mm,內部壓力點之間距離1=40mm)。將一條尺寸25mm×15mm×150mm之長條置於該壓力點,然後承受1MPa之力,溫度係以30℃/小時之速度從室溫增加至1500℃。在整個測試期間,記錄(以mm表示)長條上箭頭的變化。特定言之,在氧化鋯之同素異形性轉形下及在1400℃下測量該箭頭,並決定DTz值,其等於氧化鋯同素異形性轉形後之箭頭相對於氧化鋯同素異形性轉形前之箭頭之增加百分比,並決定D1400,其等於在1400℃下之箭頭相對於在室溫下之箭頭之增加百分比。
抵抗熱變化之能力係由借助於使尺寸30mm×30mm×30mm之樣本在介於800℃及1250℃之間經過25個循環所組成之測試來決定。在每一循環中,將樣品保持在800℃下1小時,溫度在1小時內升至1250℃及在該溫度下保持1小時。Vv值相當於在試驗開始至結束之間之體積增加(以百分比表示)。
在下表1中,*表示該實例超過本發明之範圍,ND意指<<未測定>>。
實例1相當於構成對照組之產品ER1195。
此等結果顯示本發明之測試產品呈現出色的性能模式。特定言之,該蠕變在氧化鋯之同素異形性轉形溫度下大於0.5%及Vv值保持小於10%。據觀察:根據本發明之產品之蠕變容量高於對照組產品(實例1)至少兩倍。
表1說明根據本發明之產品組合物之範圍特別窄。特定言之,在與鹼金屬氧化物、氧化硼及氧化鋁濃度之演變有關之結果中觀察到大的敏感度。
由實例4與實例6至9及13比較,顯示最低量鹼金屬氧化物(在該例中為氧化鈉)之存在具有維持提高之抗熱變化性程度之重要性。
由實例1與實例6至9及13比較,顯示最低量氧化硼之存在具有提高蠕變容量之重要性。然而,由實例6至9及13與實例3、10及11比較,顯示應限制該數量,以使B2
O3
/(Na2
O+K2
O)重量百分比之比例(B/N)小於2.5,並避免破壞抗熱變化性。
由實例6至9及13與實例2及12比較,顯示最低量氧化鋁之存在具有避免破壞抗熱變化性之重要性。
而且,其他測試已證實:根據本發明之產品亦呈現具有高氧化鋯濃度之物質之其他已識別性質,尤其抗玻璃之腐蝕性。
當然,本發明不限於敍述及代表之彼等實施例,其係提供作為非限制性說明之實例。
Claims (26)
- 一種熔融及澆鑄之耐火產品,其包含(基於氧化物之重量百分比及合計100%):
Al2 O3 /(Na2 O+K2 O)重量百分比之比例大於或等於3.5,及B2 O3 /(Na2 O+K2 O)重量百分比之比例介於0.3及2.5之間。 - 如請求項1之熔融及澆鑄之耐火產品,其中Al2 O3 1.0%。
- 如請求項2之熔融及澆鑄之耐火產品,其中Al2 O3 1.1%。
- 一種熔融及澆鑄之耐火產品,其包含(基於氧化物之重量百分比及合計100%):
B2 O3 /(Na2 O+K2 O)重量百分比之比例介於0.3及2.2之間。 - 如請求項1至4中任一項之熔融及澆鑄之耐火產品,其中B2 O3 /(Na2 O+K2 O)重量百分比之比例大於0.5。
- 如請求項1至4中任一項之熔融及澆鑄耐火產品,其中B2 O3 /(Na2 O+K2 O)重量百分比之比例大於0.8。
- 如請求項1至4中任一項之熔融及澆鑄之耐火產品,其中B2 O3 /(Na2 O+K2 O)重量百分比之比例大於1.0。
- 如請求項1至4中任一項之熔融及澆鑄之耐火產品,其中B2 O3 /(Na2 O+K2 O)重量百分比之比例小於2.2。
- 如請求項8之熔融及澆鑄之耐火產品,其中B2 O3 /(Na2 O+K2 O)重量百分比之比例小於2.0。
- 如請求項8之熔融及澆鑄之耐火產品,其中B2 O3 /(Na2 O+K2 O)重量百分比之比例小於1.5。
- 如請求項1至4中任一項之熔融及澆鑄之耐火產品,其中(Na2 O+K2 O)0.40%。
- 如請求項1至4中任一項之熔融及澆鑄之耐火產品,其中(Na2 O+K2 O)0.30%及/或B2 O3 0.30%。
- 如請求項1至4中任一項之熔融及澆鑄之耐火產品,其中(Na2 O+K2 O)0.15%及/或B2 O3 0.15%。
- 如請求項1至4中任一項之熔融及澆鑄之耐火產品,其中Al2 O3 /(Na2 O+K2 O)重量百分比之比例大於6。
- 如請求項1至4中任一項之熔融及澆鑄之耐火產品,其中"其他物質"之總重量百分比小於1.0%。
- 如請求項1至4中任一項之熔融及澆鑄之耐火產品,其中"其他物質"之總重量百分比小於0.5%。
- 如請求項1至4中任一項之熔融及澆鑄之耐火產品,其中"其他物質"(無論其組成)之重量百分比總為小於0.4%。
- 如請求項1至4中任一項之熔融及澆鑄之耐火產品,其中Fe2 O3 +TiO2 之重量百分比小於0.2%。
- 如請求項1至4中任一項之熔融及澆鑄之耐火產品,其中ZrO2 +HfO2 之含量大於93.0%。
- 如請求項19之熔融及澆鑄之耐火產品,其中ZrO2 +HfO2 之含量大於94.0%。
- 如請求項1至4中任一項之熔融及澆鑄之耐火產品,該產品係藉由包含利用以每小時低於10℃之速率進行之冷卻法凝固熔料之步驟之方法獲得。
- 如請求項21之熔融及澆鑄之耐火產品,該產品係藉由包含在氧化條件下熔化初始進料直至獲得熔料之步驟之方法獲得。
- 如請求項22之熔融及澆鑄之耐火產品,其中該氧化條件係以電弧爐獲得,其係藉由電弧本身的作用或藉由在熔池中通入氧化氣體或向該熔池中添加氧氣釋放物質。
- 一種玻璃熔爐,其包含如請求項1至23中任一項之耐火 產品。
- 如請求項24之熔爐,該耐火產品係置於計畫與溫度大於1200℃之熔化玻璃接觸之區域。
- 一種以如請求項1至23中任一項之熔融及澆鑄之耐火產品於提高根據請求項24或25之熔爐之抗蠕變性上之用途。
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| FR0853967A FR2932475B1 (fr) | 2008-06-16 | 2008-06-16 | Produit refractaire a forte teneur en zircone |
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| EP (1) | EP2303799B1 (zh) |
| JP (1) | JP5475758B2 (zh) |
| KR (1) | KR101608021B1 (zh) |
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| BR (1) | BRPI0913851A2 (zh) |
| CA (1) | CA2728061A1 (zh) |
| FR (1) | FR2932475B1 (zh) |
| RU (1) | RU2499784C2 (zh) |
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| FR2955578B1 (fr) * | 2010-01-28 | 2014-06-13 | Saint Gobain Ct Recherches | Produit refractaire a forte teneur en zircone |
| EP2632873B1 (en) * | 2010-10-29 | 2017-07-12 | Corning Incorporated | Dry process for making a large xenotime ceramic block |
| FR2986227B1 (fr) * | 2012-01-27 | 2014-01-10 | Saint Gobain Isover | Procede de production de laine minerale |
| CN104245629B (zh) * | 2012-04-06 | 2016-06-15 | 旭硝子株式会社 | 高氧化锆质电熔耐火物 |
| CN102701737B (zh) * | 2012-06-21 | 2013-10-16 | 洛阳大洋高性能材料有限公司 | 一种玻璃窑炉用高氧化锆砖的组份 |
| EP3453689B1 (en) * | 2017-09-08 | 2020-08-26 | AGC Ceramics Co., Ltd. | High-zirconia electrocast refractory and method for manufacturing the same |
| FR3072092B1 (fr) | 2017-10-11 | 2021-11-12 | Saint Gobain Ct Recherches | Procede de fabrication d'un bloc fondu a haute teneur en zircone |
| FR3121677B1 (fr) * | 2021-04-07 | 2025-10-31 | Saint Gobain Ct Recherches | Produit réfractaire à haute teneur en zircone |
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| JPH0848573A (ja) * | 1994-08-10 | 1996-02-20 | Toshiba Monofrax Co Ltd | 高ジルコニア溶融耐火物 |
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| JP2926966B2 (ja) * | 1989-11-28 | 1999-07-28 | 旭硝子株式会社 | 高ジルコニア質熱溶融鋳造耐火物 |
| RU2039026C1 (ru) * | 1993-01-18 | 1995-07-09 | Соколов Владимир Алексеевич | Плавленолитой высокоциркониевый огнеупорный материал |
| FR2701022B1 (fr) | 1993-02-03 | 1998-07-10 | Asahi Glass Co Ltd | Refractaires coules par fusion a forte teneur en zircone. |
| US5679612A (en) * | 1994-08-10 | 1997-10-21 | Toshiba Monofrax Co., Ltd. | High-zirconia fused refractories |
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| JP4979047B2 (ja) * | 1999-04-22 | 2012-07-18 | サンゴバン・ティーエム株式会社 | 高ジルコニア鋳造耐火物 |
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-
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-
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- 2009-06-16 TW TW098120182A patent/TWI450872B/zh active
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- 2009-06-16 RU RU2010150875/03A patent/RU2499784C2/ru not_active IP Right Cessation
- 2009-06-16 CA CA2728061A patent/CA2728061A1/fr not_active Abandoned
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| JPH0848573A (ja) * | 1994-08-10 | 1996-02-20 | Toshiba Monofrax Co Ltd | 高ジルコニア溶融耐火物 |
| JPH1059768A (ja) * | 1996-08-20 | 1998-03-03 | Toshiba Monofrax Co Ltd | 高ジルコニア溶融耐火物 |
| TW200800839A (en) * | 2006-06-28 | 2008-01-01 | Saint Gobain Tm Kk | High-electric resistivity, high-zirconia fused cast refractories |
Also Published As
| Publication number | Publication date |
|---|---|
| FR2932475A1 (fr) | 2009-12-18 |
| FR2932475B1 (fr) | 2010-09-03 |
| US8309482B2 (en) | 2012-11-13 |
| EP2303799B1 (fr) | 2016-03-23 |
| EP2303799A1 (fr) | 2011-04-06 |
| WO2009153517A1 (fr) | 2009-12-23 |
| TW201031618A (en) | 2010-09-01 |
| RU2010150875A (ru) | 2012-07-27 |
| US20110166008A1 (en) | 2011-07-07 |
| CN102066288A (zh) | 2011-05-18 |
| KR20110028305A (ko) | 2011-03-17 |
| JP5475758B2 (ja) | 2014-04-16 |
| CA2728061A1 (fr) | 2009-12-23 |
| JP2011524331A (ja) | 2011-09-01 |
| CN102066288B (zh) | 2015-05-13 |
| KR101608021B1 (ko) | 2016-03-31 |
| RU2499784C2 (ru) | 2013-11-27 |
| UA100893C2 (ru) | 2013-02-11 |
| BRPI0913851A2 (pt) | 2015-10-20 |
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