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US20130210605A1 - Refractory composition and process for forming article therefrom - Google Patents

Refractory composition and process for forming article therefrom Download PDF

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Publication number
US20130210605A1
US20130210605A1 US13/636,968 US201113636968A US2013210605A1 US 20130210605 A1 US20130210605 A1 US 20130210605A1 US 201113636968 A US201113636968 A US 201113636968A US 2013210605 A1 US2013210605 A1 US 2013210605A1
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United States
Prior art keywords
iii
composition
binder
refractory
kit
Prior art date
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Abandoned
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US13/636,968
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English (en)
Inventor
Jens Decker
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.)
Stellar Materials Inc
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Stellar Materials Inc
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First worldwide family litigation filed litigation Critical https://patents.darts-ip.com/?family=44673835&utm_source=google_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=US20130210605(A1) "Global patent litigation dataset” by Darts-ip is licensed under a Creative Commons Attribution 4.0 International License.
Application filed by Stellar Materials Inc filed Critical Stellar Materials Inc
Priority to US13/636,968 priority Critical patent/US20130210605A1/en
Assigned to STELLAR MATERIALS INCORPORATED reassignment STELLAR MATERIALS INCORPORATED ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: DECKER, JENS
Publication of US20130210605A1 publication Critical patent/US20130210605A1/en
Assigned to STELLAR MATERIALS, LLC reassignment STELLAR MATERIALS, LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: STELLAR MATERIALS INCORPORATED
Assigned to STELLAR MATERIALS, LLC reassignment STELLAR MATERIALS, LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: STELLAR MATERIALS INCORPORATED
Assigned to STELLAR MATERIALS, INCORPORATED reassignment STELLAR MATERIALS, INCORPORATED ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: DECKER, JENS, MINTZ, DAVID
Abandoned legal-status Critical Current

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Definitions

  • the present invention in general relates to a refractory composition and process for forming an article therefrom, and in particular a composition having crystalline AlPO 4 formed in the composition binder alone or with other binder components to produce an article with exceptional refractory corrosion resistance.
  • Cement bonded materials largely form only mechanical bonds at ambient temperature of 20° Celsius. Adhesion of these ambient temperature cured materials occurs because of the rough surface and while convenient to bond at ambient temperature are comparatively weak as compared to elevated temperature cured material and also tend to suffer from mechanical failure during heat up or when exposed to thermal stresses.
  • Representative of such materials are THERMBOND® refractories that are characterized by chemically bonding both to the cement components and to existing substrates. During the exothermic reaction between dry aggregate and a liquid activator, ionic bonding occurs to form metal-oxide phosphates to provide both coherence and adherence to impart greater strength and durability in chemically aggressive high temperature environments.
  • This material is characterized by a binder system inclusive of alkali phosphates to facilitate ambient temperature set and bonding.
  • alkali phosphates are characterized by low melting points that limit the high temperature limit of operation for the resulting material.
  • the acidity of alkali phosphates precludes introduction of a variety of dispersing or deflocculating agents that otherwise could improve handling properties of the precured cement mixture.
  • cement strengthening through densification is largely precluded as are often desirable handling methods such as pumping or shotcreting unless extra phosphoric acid is added to improve precured cement mixture flowability and extend working times.
  • a refractory composition inclusive of a phosphate binder with improved refractory alkali resistance and superior handling properties.
  • refractory articles formed from such a composition that have an extended operational lifetime relative to conventional refractory articles.
  • a refractory composition includes a plurality of aggregate ceramic particles and a binder sintered to the plurality of aggregate ceramic particles, where the binder includes crystalline aluminum orthophosphate distributed in the binder as the result of reaction of aluminum metaphosphate with alumina.
  • the plurality of aggregate ceramic particles optionally include bauxite particles.
  • the plurality of aggregate ceramic particles includes at least one of silicon carbide, fumed silica, or mullite.
  • the crystalline aluminum orthophosphate optionally has a crystal structure of berlinite. In some embodiments the crystalline aluminum orthophosphate is devoid of an amorphous glass phase.
  • compositions according to the invention optionally include facile or nonfacile additives where a nonfacile additive is optionally calcium aluminate cement, sodium silicate, polyphosphate, or organic salts.
  • a composition includes steel fiber filler.
  • compositions of the invention provide for increased strength relative to prior art refractory compositions where some embodiments of the invention have a density greater than or equal to 90% of theoretical and, optionally, a cold crush strength of greater than 100 N/mm 2 .
  • Processes for forming a refractory article include mixing aluminum metaphosphate particulate with Al 2-x MO 3 in the presence of less than 10 slurry weight percent of water or an organic solvent to form a mixture, and heating the mixture to a temperature and for a time sufficient to induce the reaction
  • M is Sb, Bi, B, Cr (III), Er, Gd (III), In (III), Ni (III), Rh (III), Sm (III), Sc (III), Tb (III), Ti (III), W (III), V (III), Yb (III), or Y (III); and x is a number between 0 and 2, inclusive.
  • the temperature used to induce the reaction is greater than 800° Celsius.
  • the process optionally further includes mixing a plurality of aggregate particles with said aluminum metaphosphate particulate and Al 2-x MO 3 .
  • at least one additive of calcium aluminate cement, sodium silicate, or polyphosphate is added to the mixture prior to heating.
  • a process optionally includes embedding steel fibers within the mixture.
  • a process optionally includes pouring the mixture into a mold having a shape complementary to an article and allowing the mixture to dry to form a piece of greenware, and heating the greenware to induce the reaction.
  • a mold is optionally a plaster mold.
  • kits are provided optionally for use in forming an inventive composition where the kit includes aluminum metaphosphate and a nonfacile additive. Instructions are optionally provided with the kit where the instructions are to combine aluminum metaphosphate with alumina and less than 10 slurry percent water or organic solvent for casting and then firing at a temperature above 800° Celsius. to form aluminum orthophosphate as a continuous binder matrix phase.
  • a nonfacile additive optionally comprises calcium aluminate cement, sodium silicate, sodium polyphosphates, or combinations thereof.
  • a kit optionally further includes a facile additive.
  • a kit includes steel fiber filler.
  • the present invention has utility as a refractory composition inclusive of a variety of aggregate particles, fibers, and fillers joined by an in situ formed binder containing crystalline aluminum orthophosphate, AlPO 4 .
  • a common crystalline form of aluminum orthophosphate is berlinite.
  • a kit is provided to produce a refractory binder.
  • the kit includes aluminum metaphosphate, Al(PO 3 ) 3 , calcium aluminate, along with instructions to mix the contents with a quantity of water and a source of refractory aggregate, and after set firing to form a refractory material.
  • the aluminum metaphosphate reacts to form crystalline aluminum orthophosphate, AlPO 4 .
  • Aluminum orthophosphate is the thermodynamic product upon heating to a temperature greater than about 580° Celsius. with a decomposition temperature of about 1650° Celsius.
  • the resultant refractory composition is amenable to incorporation of reinforcing materials such as steel fibers and is operative with aggregate particulate including silicon carbide, mullite, alumina, titania, and combinations thereof.
  • Such a refractory composition is readily formed with a density of greater than 90%, a theoretical density and cold crush strengths in excess of 88 Newtons per square millimeter.
  • the cast form of an article from an inventive composition has sufficient green strength to be handled and optionally machined prior to firing to provide a refractory article with superior strength and alkali resistance, as compared to conventional materials.
  • An inventive bindery for a refractory material includes aluminum metaphosphate that is mixed aggregate ceramic particles and processed under conditions to afford aluminum orthophosphate as a crystalline binder.
  • the binder aluminum orthophosphate has as a predominant phase berlinite. It is appreciated that aluminum metaphosphate as binder precursor is amenable to inclusion in a kit as aluminum metaphosphate is far less hygroscopic as compared to phosphoric acid, more pH neutral (around pH5) and is commercially available in a variety of particle mesh sizes.
  • Aluminum orthophosphate appears to be a thermodynamically stable phase that is formed upon heating the reagents to a temperature above about 580° Celsius.
  • Aluminum orthophosphate is noted to have a decomposition temperature of about 1650° Celsius. at ambient pressure. It is appreciated that the formation temperature of aluminum orthophosphate varies according to predictable thermodynamic relationships when the reaction proceeds at pressures other than atmospheric pressure. It is appreciated that formation of a refractory composition according to the present invention readily occurs through firing the green form of an article through hot isostatic pressing (HIP). It is appreciated that a mixed metal orthophosphate is readily formed according to the reaction:
  • M is Sb, Bi, B, Cr (III), Er, Gd (III), In (III), Ni (III), Rh (III), Sm (III), Sc (III), Tb (III), Ti (III), W (III), V (III), Yb (III), or Y (III); and x is a number between 0 and 2, inclusive.
  • Equation (II) in addition to being operative as a binder for a refractory composition, also is appreciated to be operative in catalytic and phosphor applications.
  • the amount of aluminum metaphosphate present to form a matrix around refractory ceramic particulate depends on factors including size of the ceramic particulate, desired interparticle separation, morphology, size of primary crystals and oxide state.
  • aluminum metaphosphate is present between 2 and 20 total weight percent of the fully formulated refractory composition casting slurry.
  • alumina is present in excess of molar stoichiometry of alumina metaphosphate. It is appreciated that alumina is present as aggregate ceramic particles or alternatively is added as a minor quantity of the ceramic particles for reaction with the alumina metaphosphate.
  • a quantity of water or organic solvent is added to afford a slurry of a desired viscosity.
  • organic solvents illustratively include alcohols, ketones, esters, ethers, amides, amines, glycols, alkanes, and the like.
  • organic solvents are liquids below 200° Celsius. and preferably are liquids at 20° Celsius.
  • Typical loadings of water or solvents range from 2-20 total weight percent of a fully formulated refractory composition slurry.
  • additives are included that are consumed during berlinite formation, these additives provided to promote ease of handling.
  • Such additives illustratively include surfactants; polymerizable organic monomers or oligomers, deflocculants; polymers; and organic acids such as citric, and oxalic. While one of ordinary skill in the art can readily adjust slurry viscosity and green strength through the inclusion of such additives, typically each such additive is present from 0.01-5 total weight percent of a fully formulated refractory composition slurry. It is appreciated that the inclusion of organic monomeric or oligomeric polymerizable materials that upon cure can improve the green strength of the composition prior to firing or reaction according to Equation (I) or (II). The resultant polymer is decomposed and therefore not present in the resultant refractory composition. Exemplary of such organic polymers are acrylic acids, acrylates, polyethylene glycols, and polycarboxylate ethers, which are added as polymeric precursors or slurry soluble preformed polymers.
  • Handling properties of an inventive refractory composition slurry and the green strength of an inventive composition form after drying are also modified through inclusion of nonfacile additives. While the amount of such nonfacile additives is controlled by factors including desired green strength, refractory composition, working environment, temperature and corrosivity, desired cold crush strength, and setting time, working time and curing time, typical loadings of such nonfacile additives range from 0.1 to 10 total weight percent of a fully formulated refractory composition slurry.
  • nonfacile additives operative herein include calcium aluminate cement, sodium silicate, fumed silica, alkali metal or alkali earth polyphosphates, and organic salts like citric, oxalic or nitric acids, calcium silicate cement, potassium silicate, lithium silicate.
  • nonfacile additive is present in a quantity such that the aluminum orthophosphate forms a continuous matrix phase.
  • Ceramic particle aggregate embedded within an aluminum orthophosphate binder according to the present invention is limited only by the desired properties of the resultant refractory composition and compatibility with aluminum orthophosphate binder.
  • Operative ceramic particle aggregates in the present invention illustrative include bauxite, tabular alumina, mullite, silicon carbide, fused silica, rutile, and andalusite, sillimanite, magnesite, forsterite, kyanite, Mg spinell, and chromium oxide.
  • Typical loadings of aggregate ceramic particles range from 50-95 weight percent of a fully formulated refractory composition slurry.
  • Typical aggregate particle sizes range from 0.1 to 1000 microns. It is appreciated that the aggregate particles can be in a variety of forms including spherical, polyhedral, irregular, and combinations thereof.
  • An inventive formulation optionally includes strengthening fibers such as steel fibers as detailed in U.S. Pat. No. 4,366,255. Typical loadings of fibers are from 0 to 50 total weight percent of a refractory composition slurry.
  • Other strengthening fiber fillers operative herein include carbon fibers with the recognition that firing occurs in a reducing atmosphere.
  • 5% aluminum metaphosphate was mixed into bauxite aggregate along with 41 ⁇ 2 total weight percent water and 0.1% polyethylene glycol having a molecular weight of more than 300 grams per mole. Upon drying and firing at 800° Celsius. for 5 hours, a ceramic was obtained having a crystalline aluminum orthophosphate continuous binder matrix phase as determined by x-ray powder diffraction.
  • Example 1 The slurry of Example 1 was modified to include 5% by slurry weight calcium aluminate cement with comparable results.
  • Example 2 To the slurry of Example 2, dry sodium silicate was added to 0.015 total percent. An increase in green strength is noted and faster setting time that facilitated ease of demolding and also produced a crystalline aluminum orthophosphate matrix phase.
  • Example 1 To the slurry of Example 1, 0.015 total weight percent dry sodium silicate was added to achieve an increase in green strength without resort to the calcium aluminate cement per Example 3. A formulation containing 88 total slurry weight percent bauxite, 0.015% dry sodium silicate, 5% aluminum metaphosphate, 0.1% polyethylene glycol, and the remainder water. After firing at 800° Celsius., cold crush strength of 200 N/mm 2 was obtained. To determine the permanent linear change and the resultant refractory material, the slurry was fired at temperatures of 1100° Celsius., 1370° Celsius., and 1600° Celsius. Permanent linear change at 1100° Celsius. was 0.0%, ⁇ 0.2% shrinkage at 1370° Celsius., and ⁇ 0.2% shrinkage at 1600° Celsius. The results confirm that the aluminum orthophosphate system does not create a significant melt phase.
  • Hot modulus of rupture tests were conducted on material fired at 800° Celsius.
  • the hot modulus of rupture is as follows for the noted test temperatures: 815° Celsius. (38 N/mm 2 ); 1100° Celsius. (35 N/mm 2 ); and 1200° Celsius. (22 N/mm 2 ).
  • the density of the material in four separate tests ranged between 181.7 and 183.1 pounds per cubic foot.
  • the total alumina content adds up to 88% alumina.
  • Fume silica is an additive that fills submicron pores and improves the flow characteristics and lowers the water content at the same time. It is almost 100% pure SiO2.
  • Example 8 contains 65% fused silica but the total SiO2 content is 70% due to the 5% SiO2 from fume silica.
  • Example 4 The slurry of Example 4 was cast in a plaster mold and also fired at 815° Celsius.
  • the hot modulus of rupture, porosity and density results for casting performed in a plaster mold relative to a non-permeable acrylic mold as used in Example 4 are provided in Table 2.
  • Example 4 was used in plaster mold slip casting to form abrasion plates for use in coal fired burners or boiler tubes; launder segments, tap out blocks, ladle slide gates for steel forging, wear plates for ladles and in launders, and wear segments in metal-containing vessels for aluminum, copper, zinc, lead, cast iron, or other materials.
  • the greenware had sufficient strength to be amenable to additional machining prior to firing.
  • shrinkage between a mold form and the fired article was minimal. Drying at 105° Celsius. to volatilize water from the slurry prior to firing occurred.
  • a molding was fast fired and noted to have a green strength of 33 N/mm 2 after drying at 104° Celsius.: 63 N/mm 2 and after firing at 815° Celsius.: 162 N/mm 2 .
  • the resultant material was subjected to an Alcoa cup test and rated excellent/good.
  • a larger test shape was filled with 15 lbs of steel-fiber in a form.
  • the voids were filled with 29 lbs of slurry.
  • the slurry contained 61% calcined alumina, 13% fume silica, 13% calcium aluminate cement, 15% AMP and mixed with 15% water which resulted in 37% steel-fiber content in the fired shape.
  • a cold crush strength of 132 N/mm 2 was noted and a modulus of rupture of 13. It is of note that the slurry contained no aggregate above 45 microns that would have contributed to the strength of the fired article.

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US9586866B2 (en) * 2010-03-23 2017-03-07 Stellar Materials Incorporated Refractory composition and process for forming article therefrom
CN109072085A (zh) * 2016-02-25 2018-12-21 新日铁住金株式会社 炼焦炉用预制块状耐火物
CN113860918A (zh) * 2021-11-15 2021-12-31 北京中科海钠科技有限责任公司 一种耐碱性涂层浆料和具有耐碱性涂层的坩埚及制备方法
CN115368151A (zh) * 2022-08-18 2022-11-22 河南省宏达炉业有限公司 一种抗剥落和抗水蒸气侵蚀的耐火浇注料及其制备方法
WO2023077194A1 (en) * 2021-11-05 2023-05-11 1414 Degrees Limited Composite thermal member and method for forming same
CN117658649A (zh) * 2023-12-04 2024-03-08 宜兴瑞泰耐火材料工程有限公司 一种cfb靶区专用可塑料及其制备工艺

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WO2014031574A1 (en) * 2012-08-21 2014-02-27 Stellar Materials Incorporated Refractory composition and process for forming article therefrom
CN104628298B (zh) * 2013-11-06 2016-08-10 郭太宗 水泥抑碱添加剂
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BR112017025791A2 (pt) * 2015-05-31 2018-08-07 Besim Pty Ltd material de isolamento térmico
CN110590383A (zh) * 2019-08-23 2019-12-20 河南恒耐尔耐火材料有限公司 一种热态修补喷涂料及其制备方法
CN110563470A (zh) * 2019-08-23 2019-12-13 河南恒耐尔耐火材料有限公司 一种高强防爆喷涂料及其制备方法
DE102020208242B4 (de) 2020-07-01 2024-02-29 Refratechnik Holding Gmbh Trockenstoffgemisch für einen Versatz zur Herstellung eines grobkeramischen feuerfesten, nicht-basischen Erzeugnisses, Feuerbetonversatz und derartiges Erzeugnis sowie Verfahren zu seiner Herstellung, Zustellung und Industrieofen, Rinnentransportsystem oder mobiles Transportgefäß, Verwendung des Trockenstoffgemisches und des Feuerbetonversatzes
EP4194424A1 (en) * 2021-12-10 2023-06-14 ImerTech SAS Castable refractory compositions
CN114956571B (zh) * 2022-06-07 2023-08-29 佛山东鹏洁具股份有限公司 一种毛孔组合补釉的制备方法及其产品、使用方法

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US9586866B2 (en) * 2010-03-23 2017-03-07 Stellar Materials Incorporated Refractory composition and process for forming article therefrom
WO2015094218A1 (en) * 2013-12-18 2015-06-25 Halliburton Energy Services, Inc. Corrosion-resistant refractory binder compositions and oil well completion and production operations
GB2536578A (en) * 2013-12-18 2016-09-21 Halliburton Energy Services Inc Corrosion-resistant refractory binder compositions and oil well completion and production operations
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CN109072085A (zh) * 2016-02-25 2018-12-21 新日铁住金株式会社 炼焦炉用预制块状耐火物
WO2023077194A1 (en) * 2021-11-05 2023-05-11 1414 Degrees Limited Composite thermal member and method for forming same
CN113860918A (zh) * 2021-11-15 2021-12-31 北京中科海钠科技有限责任公司 一种耐碱性涂层浆料和具有耐碱性涂层的坩埚及制备方法
CN115368151A (zh) * 2022-08-18 2022-11-22 河南省宏达炉业有限公司 一种抗剥落和抗水蒸气侵蚀的耐火浇注料及其制备方法
CN117658649A (zh) * 2023-12-04 2024-03-08 宜兴瑞泰耐火材料工程有限公司 一种cfb靶区专用可塑料及其制备工艺

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