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CN100408495C - 玻璃熔炉用耐火材料系统 - Google Patents

玻璃熔炉用耐火材料系统 Download PDF

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CN100408495C
CN100408495C CNB2003101246392A CN200310124639A CN100408495C CN 100408495 C CN100408495 C CN 100408495C CN B2003101246392 A CNB2003101246392 A CN B2003101246392A CN 200310124639 A CN200310124639 A CN 200310124639A CN 100408495 C CN100408495 C CN 100408495C
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M·W·安德森
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Abstract

玻璃熔炉用耐火材料系统，包含氧化铝、氧化锆和与二氧化硅粘合剂混合的二氧化硅。耐火材料可以形成为耐火材料块或直接在玻璃熔炉的磨损部分上形成。可以采用铸造、泵送或喷浆法方法形成耐火材料。

Description

玻璃熔炉用耐火材料系统
相关申请
本申请要求2002年12月10日申请的美国临时专利申请号为No.60/432,503的优先权，因此在这里将其全文引入本文以供参考。
技术领域
本发明一般涉及玻璃熔炉用耐火材料。更具体地说，本发明涉及用于玻璃熔炉衬里的硅胶耐火材料。
背景技术
玻璃熔炉是用于熔化和容纳玻璃的容器形状的具有耐火衬里的容器。在熔化工艺中，将输入的制玻璃的原料加热至大约2800°F(1550℃)。制玻璃的原料通常包括碎玻璃和配料的混和物。碎玻璃是来自于制造过程中的破碎玻璃。配料包括砂子(二氧化硅)，石灰(石灰石或还原为氧化钙的碳酸钙)，无水碳酸钠(氧化钠)，有时还有其它的原料，诸如长石，芒硝和金属氧化物。在熔化工艺期间，碎玻璃首先熔化以增加传送给配料的热量并且减少熔化时间。
玻璃熔炉包括坩埚炉，玻璃熔炉或池炉等等。坩埚炉具有一个坩埚或碗状外形构造，并且通常用于熔化较少量的玻璃。玻璃熔炉从较小的常用熔炉到较大的连续熔化熔炉都有。常用熔炉经常充满用于过夜熔化的制玻璃的原料。连续熔化熔炉是大的炉，其中制玻璃的原料在一端填充，熔化，并流向另一端以便移除。玻璃熔炉通常构造为具有在钢架之内的分离的耐火砖或块。该块安装在一起而不用砂浆，并且典型的摆成矩形形状来容纳熔融的玻璃。来自于钢架和外部块的机械压力使块保持在一起。玻璃熔炉通常具有回热室来预热助燃空气以取得更高的火焰温度。
耐火块通常受到来自熔融玻璃和制玻璃的原料供料的相当严重的磨损。熔融玻璃具有高腐蚀性。耐火块通常是由含有氧化铝、氧化锆和二氧化硅(AZS)的复合粘土构成。AZS耐火块是由熔融的原料铸模而制成的，其在硬化之后经机械加工。
在连续熔化熔炉中，熔化工艺持续进行基本上不间断直至熔炉不能再用。在熔化工艺期间，耐火块会有深深的划痕并且在熔融玻璃腐蚀或溶解耐火材料的地方会产生磨损点或部分。磨损点通常一直生长到该耐火材料不能容纳熔融的玻璃。磨损点会缩短玻璃熔炉的使用寿命并且这种情况经常是无法预知的，因而中断了熔融玻璃的生产。
发明内容
根据本发明，提供了一种耐火材料组合物，包含一种二氧化硅粘合剂和第一组组分，第一组组分包含50至70wt％的氧化铝，10至25wt％的锆石，和15至35wt％的富铝红柱石，其中二氧化硅粘合剂占第一组组分干重的5wt％至20wt％范围之内。
根据本发明，还提供了一种制备玻璃熔炉用耐火材料的方法，包括：提供一种包含一种二氧化硅粘合剂65至80wt％的氧化铝、7至15wt％的氧化锆和10至20wt％的二氧化硅的耐火材料组合物；和在熔炉表面上形成耐火材料组合物。
本发明提供了一种制备玻璃炉用耐火材料的方法，包括：提供一种耐火材料组合物，其中该耐火材料组合物由一种二氧化硅粘合剂和包含50至70wt％的氧化铝、10至25wt％的锆石和15至35wt％的富铝红柱石的第一组分形成，和在熔炉表面上形成耐火材料组合物。
本发明提供了一种玻璃熔炉用耐火材料组合物。耐火组合物包括，与二氧化硅粘合剂混合的第一组组分。第一组组分包括氧化铝、氧化锆和二氧化硅。得到的耐火材料可以制作成耐火块或直接在玻璃熔炉的磨损部分上面形成。耐火材料可以通过铸造、泵送或喷浆法的方法形成。
对于本领域的熟练人员而言，通过检验下述的附图和详细描述，本发明的其它系统、方法、特征和优点将会是或将会变得明显。所有这种附加的系统、方法、特征和优点将包括在本说明书、本发明的范围内，并受到所附权利要求书的保护。
附图说明
参考下述附图和详细描述，本发明可以被更好的理解。附图中的部件无需按比例，重点放在说明本发明的原理上。此外，在整个不同的视图中，图中相同的参考数字代表相应部分。
图1是代表本发明的一个实施方案，具有硅胶耐火材料系统的玻璃熔炉的局部透视图。
具体实施方式
图1代表带有耐火材料系统的玻璃熔炉或熔炉100的局部透视图。玻璃熔炉100可以具有额外的特征和部件诸如熔化和精炼室、回热器、燃烧器等等，这些未示出。玻璃熔炉100具有支撑炉床104和侧壁106的框架102。框架102由钢板和梁构成，并且可以含有其它适合用于玻璃熔炉的材料。侧壁106从炉床104垂直延伸形成用于熔化和容纳玻璃的容器形状。炉床104具有一个或更多耐火材料的炉床衬里108。侧壁106也具有一个或更多耐火材料的侧壁衬里。衬里可以具有相同或不同的耐火材料。耐火材料是砖、块或单片构造。块包含氧化铝、氧化锆、二氧化硅，其组合，或另一种适合玻璃熔炉用的耐火材料。块也可以包含二氧化硅粘合剂。玻璃熔炉100还具有在炉床104的磨损部分上面形成的补丁衬里110。磨损部分可能位于沿玻璃熔炉内侧的任何地方，包括炉床和侧壁以及熔融玻璃之上或之下。在炉床104和/或侧壁106上可能有一个或更多补丁衬里。补丁衬里110包含耐火材料，诸如硅胶耐火材料。当具体构造示出时，玻璃熔炉100可以具有其它构造，包括带有更少或额外部件的那些玻璃熔炉。
在一个实施方案中，耐火材料包含二氧化硅粘合剂与第一组组分的混合物。二氧化硅粘合剂基于第一组组分的干重计，在大约5％(重量)至大约20％(重量)范围内，优选基于第一组组分的干重计在6％和12％(重量)之间。在一个实施方案中，粘合剂是硅胶粘合剂。第一组组分包括氧化铝(Al2O3)，氧化锆(ZrO2)，和二氧化硅(SiO2)。第一组组分可以是干的或湿的，并且还可以包括其它矿物质，固化剂如氧化镁(MgO)，和/或流动调节剂。
氧化铝、氧化锆和二氧化硅提供强度和耐蚀性。氧化铝可以由高铝含量的集合体提供，诸如刚玉或白色熔融氧化铝提供。氧化铝也可以是反应性的或煅烧的。氧化锆可以由锆石粉或含氧化锆的材料提供。二氧化硅可以由富铝红柱石(硅酸铝)，微粒硅，硅胶等等提供。
二氧化硅粘合剂将第一组组分以单片状形式保持或粘合在一起。在一个实施方案中，粘合剂是硅胶粘合剂。该硅胶粘合剂包含在水中的硅胶，其中硅胶在大约15％(重量)至大约70％(重量)范围内。在一个实施方案中，硅胶的平均粒径可在大约4纳米至大约100纳米范围之内。
第一组组分包括大约50％(重量)(wt％)至大约70wt％的氧化铝，大约10至大约25wt％的锆石，和大约15至大约35wt％富铝红柱石。优选，第一组组分包括大约55wt％至大约60wt％氧化铝，大约15至大约20wt％锆石，和大约21至大约27wt％富铝红柱石。可以使用其它比例的第一组组分。第一组组分可以包括其它化合物诸如大约0.1％(重量)的氧化镁。可以调整氧化镁的量来增加或减少胶体系统耐火材料的固化时间。第一组组分也可以包含流动调节剂来增强或改变流动性能，从而在固化之前形成该硅胶耐火材料。可以在加入硅胶粘合剂之前，混合第一组组分。得到的耐火材料包含大约65至大约80wt％氧化铝，大约7至大约15wt％氧化锆，和大约10至大约20wt％二氧化硅。
耐火材料组合物还可以包含大约70至大约75wt％的氧化铝，大约9至大约13wt％的氧化锆，和大约13至大约17wt％的二氧化硅。
为了说明的目的，而不是为了加以限制，表1提供了用于硅胶耐火材料系统的第一组组分的示范类型和比例。
表1
  原料   网孔尺寸   Wt％
  刚玉   1/4×8   19.296
  刚玉   8×14   19.296
  刚玉   -28M   4.824
  锆石粉   -325M   16.844
  熔融富铝红柱石   -40M   24.12
  反应性氧化铝(例如，来自于Alcan的CAR 120B)   -325M   4.824
  煅烧氧化铝(例如，来自于Alcan的CAR 60RG)   -325M   9.648
  铝粉   -100M   0.965
  MgO98％   -200M   0.096
这些组分在市场上能从Alcon和其它供应商处买到。在与硅胶粘合剂混合之前，可以将第一组组分混合在一起。在与硅胶粘合剂混合前，第一组组分也可以是湿的或干的。该混合物固化成为硅胶耐火材料，其包含大约72.5％(重量)的氧化铝，大约11.2％(重量)的氧化锆，和大约15.6％(重量)的二氧化硅。该硅胶耐火材料可以铸造成块以便随后用于玻璃熔炉中，或可以直接形成在玻璃熔炉的磨损部分上。在磨损部分上可以使用一种或更多的耐火材料形成方法形成硅胶耐火材料，诸如铸造、泵送或喷浆法(shotcreting)(使用促凝剂的无定型泵送)。可以在侧壁或炉床的一个或更多的部分上形成硅胶耐火材料。可以直接在磨损部分上形成硅胶耐火材料，而无需更换玻璃熔炉的耐火材料块。
已经描述和说明了本发明的各种各样的实施方案。然而，这些描述和说明仅是举例。其它的实施方案和实施也可能在本发明的范围之内，并且对于本领域普通熟练人员来说将是明显的。因此，本发明不限制在本说明书中的具体细节，有代表性的具体实施方案，和说明性举例中。所以，除必需依据权利要求书和等价的保护范围之外，本发明不受限制。

Claims (15)

1. 一种耐火材料组合物，包含一种二氧化硅粘合剂和第一组组分，第一组组分包含50至70wt％的氧化铝，10至25wt％的锆石，和15至35wt％的富铝红柱石，其中二氧化硅粘合剂占第一组组分干重的5wt％至20wt％范围之内。
2. 根据权利要求1的耐火材料组合物，其特征在于，第一组组分包含55至60wt％的氧化铝，15至20wt％的锆石，和21至27wt％的富铝红柱石。
3. 根据权利要求1的耐火材料组合物，其特征在于，二氧化硅粘合剂是一种含水硅胶粘合剂。
4. 根据权利要求3的耐火材料组合物，其特征在于，硅胶粘合剂占第一组组分干重的8wt％至12wt％范围之内。
5. 根据权利要求1的耐火材料组合物，其特征在于，进一步包含固化剂。
6. 根据权利要求5的耐火材料组合物，其特征在于，固化剂是氧化镁。
7. 根据权利要求1的耐火材料组合物，其特征在于，耐火材料组合物在玻璃熔炉的至少一个磨损部分上形成。
8. 一种制备玻璃熔炉用耐火材料的方法，包括：
提供一种包含一种二氧化硅粘合剂和65至80wt％的氧化铝、7至15wt％的氧化锆和10至20wt％的二氧化硅的耐火材料组合物；和
在熔炉表面上形成耐火材料组合物。
9. 权利要求8的方法，其特征在于，二氧化硅粘合剂是占第一组组分干重的5wt％至20wt％范围内的含水硅胶粘合剂。
10. 权利要求8的方法，其特征在于，进一步包括将第一组组分和含水二氧化硅粘合剂混合的步骤。
11. 权利要求8的方法，其特征在于，耐火材料组合物是通过铸造形成的。
12. 权利要求8的方法，其特征在于，耐火材料组合物是通过泵送形成的。
13. 权利要求8的方法，其特征在于，耐火材料组合物是通过喷浆法形成的。
14. 权利要求8的方法，其特征在于，耐火材料组合物进一步包含固化剂。
15. 一种制备玻璃炉用耐火材料的方法，包括：
提供一种耐火材料组合物，其中该耐火材料组合物由一种二氧化硅粘合剂和包含50至70wt％的氧化铝、10至25wt％的锆石和15至35wt％的富铝红柱石的第一组分形成，和
在熔炉表面上形成耐火材料组合物。
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