JP2014129199A - 高ジルコニア質電鋳耐火物 - Google Patents
高ジルコニア質電鋳耐火物 Download PDFInfo
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Abstract
【解決手段】化学成分として、酸化物基準で、ZrO2が96.5〜98.5質量%、SiO2が0.8〜2.7質量%、Na2O及びK2Oの合量が0.04〜0.35質量%、B2O3が0.02〜0.18質量%の範囲で含有され、かつ、前記Na2O、K2O及びB2O3の含有量が次の式(1)
0.03 ≧ CB2O3−(CNa2O+CK2O) …(1)
(式中、CNa2OはNa2Oの含有量、CK2OはK2Oの含有量、CB2O3はB2O3の含有量であり、これら含有量はいずれも耐火物中における質量%で表す。)の関係を満たす高ジルコニア質電鋳耐火物。
【選択図】図1
Description
0.03 ≧ CB2O3−(CNa2O+CK2O) …(1)
(式中、CNa2OはNa2Oの含有量、CK2OはK2Oの含有量、CB2O3はB2O3の含有量であり、これら含有量はいずれも耐火物中における質量%で表す。)の関係を満たすことを特徴とする。
0.03 ≧ CB2O3−(CNa2O+CK2O) …(1)
(式中、CNa2OはNa2Oの含有量、CK2OはK2Oの含有量、CB2O3はB2O3の含有量であり、これら含有量はいずれも耐火物中における質量%で表す。)
残存膨張率(%)=(熱サイクル試験後の体積/熱サイクル試験前の体積)−1)×100
0.02 ≧ CB2O3−(CNa2O+CK2O) …(2)
0.01 ≧ CB2O3−(CNa2O+CK2O) …(3)
(式中、CNa2OはNa2Oの含有量、CK2OはK2Oの含有量、CB2O3はB2O3の含有量であり、これら含有量はいずれも耐火物中における質量%で表す。)
CNa2O+CK2O+CB2O3 ≦ 0.3 …(4)
(式中、CNa2OはNa2Oの含有量、CK2OはK2Oの含有量、CB2O3はB2O3の含有量であり、これら含有量はいずれも耐火物中における質量%で表す。)
CNa2O+CK2O+CB2O3 ≦ 0.27 …(5)
CNa2O+CK2O+CB2O3 ≦ 0.24 …(6)
(式中、CNa2OはNa2Oの含有量、CK2OはK2Oの含有量、CB2O3はB2O3の含有量であり、これら含有量はいずれも耐火物中における質量%で表す。)
これらの微量成分はガラスマトリックス中に含有され、耐火物に種々の特性を付与している。そして、これら微量成分が、亀裂境界線、残存膨張境界線、各成分の上限値及び下限値で囲まれる領域(斜線領域+格子斜線領域)で含有されると、本発明の効果を奏する耐火物が得られる。
さらにマトリックスガラス中の微量成分は、ガラスマトリックスの滲みだし防止まで考慮すると、亀裂境界線、残存膨張境界線、滲みだし境界線、各成分の上限値及び下限値で囲まれる領域(格子斜線領域)で含有されることが好ましい。
鋳塊の外観上の亀裂について次のように評価した。
まず、高ジルコニア質電鋳耐火物の鋳塊から押し湯部分を切除して、厚み200mm×幅300mm×高さ700mm(質量:約230kg)の電鋳耐火物を製造した。次いで、その電鋳耐火物の表面を研磨したときに肉眼で確認できる亀裂の有無を、次の基準で評価した。
◎:表面から15mm研磨除去すると、ほぼ全ての亀裂を除去できる。
○:表面から30mm研磨除去すると、ほぼ全ての亀裂を除去できる。
×:表面から30mm研磨除去しても、亀裂は除去できない。
製造した電鋳耐火物から厚み50mm×幅50mm×高さ50mmの試料を切り出し、800℃と1250℃の間を40回往復させる加熱・冷却を電気炉中で実施した。この際、室温から800℃の間の加熱は毎時160℃にて行い、ここから、800℃到達後直ちに1250℃への加熱を毎時450℃にて行い、1250℃到達後直ちに800℃までの冷却を毎時450℃にて行って1回の熱サイクルとし、800℃と1250℃とを往復する熱サイクルを40回繰り返した。最終の熱サイクル後は毎時160℃にて800℃から室温まで冷却した。この試験前及び試験後で試料の寸法を測定し、その寸法変化から残存膨張率を求めた。このとき得られた残存膨張率を、次の基準により評価した。
◎:残存膨張率が15%以下である。
○:残存膨張率が25%以下である。
×:残存膨張率が25%を超えている。
製造した電鋳耐火物から直径30φmm×高さ30mmの試料を切り出し、1500℃で16時間加熱した。この加熱後に、試料表面においてガラスの滲みだしを目視で確認し、次の基準により評価した。
◎:滲みだしが観察されない。
○:1〜3個の滲みだしが観察される。
△:4〜6個の滲みだしが観察される。
×:7個以上の滲みだしが観察される。
製造した電鋳耐火物から厚み24mm×幅12mm×高さ105mmの試料を切り出し、1680℃のガラスに48時間浸漬し、その浸食深さを次の基準により評価した。浸食深さは、ZrO2の含有量が95質量%の耐火物(AGCセラミックス社製、商品名:ZB−X950)に対して上記耐食試験を行ったときの侵食量を基準(100%)とし、質量基準で、試料の侵食量を相対的に表し、次の基準により評価した。
◎:侵食量が88%以下である。
○:侵食量が92%以下である。
×:侵食量が92%を超えている。
総合評価は、上記4項目の特性評価について、次の基準により評価した。
◎:上記4項目が全て◎である。
○:耐食性が◎で、残りの3項目が全て×ではない。
×:上記4項目の1つ以上に×がある。
表1から明らかなように、例1〜18の高ジルコニア質電鋳耐火物は、耐食性が非常に優れており、ガラス溶融炉への使用に(特に、高温溶解する場合にも)適しており、製造された鋳塊に生じる亀裂の深さが浅いため、製造効率を向上できるとともに、大型の鋳造耐火物の製造も可能である。また、この高ジルコニア質電鋳耐火物は、残存膨張率が小さく使用時の温度変化に対する割れ耐性が高いため、長寿命な鋳造耐火物とできる。さらに、マトリックスガラスの滲みだしも十分に抑制され、使用時に、溶融ガラス中に耐火物中のガラス成分が滲みだすおそれが少なく、溶融ガラスへの汚染の心配も低い。
例19〜22、例28および例30の耐火物は、B2O3の含有量が低いため、製造時深い亀裂が生じてしまっており、鋳塊の表面から20mm研磨しても亀裂が除去できなかった。従って、これらの耐火物は、たとえ耐食性や温度変化に対する割れ耐性等の点に問題がなくとも、生産性に問題がある。
例27は、図2の中にプロットされていないが、B2O3の含有量が高い例であり、Na2O及びK2Oの含有量の合量とB2O3の含有量との差が0.03未満である。この耐火物は、残存膨張が高いため温度変化に対する割れ耐性が不十分である。
Claims (11)
- 化学成分として、酸化物基準で、ZrO2が96.5〜98.5質量%、SiO2が0.8〜2.7質量%、Na2O及びK2Oの合量が0.04〜0.35質量%、B2O3が0.02〜0.18質量%の範囲で含有され、かつ、前記Na2O、K2O及びB2O3の含有量が次の式(1)
0.03 ≧ CB2O3−(CNa2O+CK2O) …(1)
(式中、CNa2OはNa2Oの含有量、CK2OはK2Oの含有量、CB2O3はB2O3の含有量であり、これら含有量はいずれも耐火物中における質量%で表す。)の関係を満たすことを特徴とする高ジルコニア質電鋳耐火物。 - さらに、Al2O3が0.1〜0.6質量%の範囲で含有される請求項1記載の高ジルコニア質電鋳耐火物。
- CuOを実質的に含有しない請求項1又は2記載の高ジルコニア質電鋳耐火物。
- P2O5の含有量が0.04質量%以下である請求項1乃至3のいずれか1項記載の高ジルコニア質電鋳耐火物。
- 前記Na2Oの含有量が0.04〜0.25質量%である請求項1乃至4のいずれか1項記載の高ジルコニア質電鋳耐火物。
- Fe2O3+TiO2の含有量が0.3質量%以下である請求項1乃至5のいずれか1項記載の高ジルコニア質電鋳耐火物。
- MgO及びCaOの含有量が共に0.05質量%以下である請求項1乃至6のいずれか1項記載の高ジルコニア質電鋳耐火物。
- 前記B2O3、Na2O及びK2Oの含有量が、次の式(4)
CNa2O+CK2O+CB2O3 ≦ 0.3 …(4)
(式中、CNa2OはNa2Oの含有量、CK2OはK2Oの含有量、CB2O3はB2O3の含有量であり、これら含有量はいずれも耐火物中における質量%で表す。)の関係を満たすことを特徴とする請求項1乃至7のいずれか1項記載の高ジルコニア質電鋳耐火物。 - 嵩比重が5.4以上である請求項1乃至8のいずれか1項記載の高ジルコニア質電鋳耐火物。
- 気孔率が1.5%以下である請求項1乃至9のいずれか1項記載の高ジルコニア質電鋳耐火物。
- その質量が200kg以上である請求項1乃至10のいずれか1項記載の高ジルコニア質電鋳耐火物。
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EP3453689A1 (en) | 2017-09-08 | 2019-03-13 | AGC Ceramics Co., Ltd. | High-zirconia electrocast refractory and method for manufacturing the same |
KR20190028309A (ko) | 2017-09-08 | 2019-03-18 | 에이지씨 가부시키가이샤 | 고지르코니아질 전기 주조 내화물 및 그 제조 방법 |
WO2022114022A1 (ja) | 2020-11-24 | 2022-06-02 | サンゴバン・ティーエム株式会社 | 高ジルコニア電気溶融鋳造耐火物 |
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