JP6607575B2 - 高アルミナ含量を有する製品 - Google Patents
高アルミナ含量を有する製品 Download PDFInfo
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- JP6607575B2 JP6607575B2 JP2016528633A JP2016528633A JP6607575B2 JP 6607575 B2 JP6607575 B2 JP 6607575B2 JP 2016528633 A JP2016528633 A JP 2016528633A JP 2016528633 A JP2016528633 A JP 2016528633A JP 6607575 B2 JP6607575 B2 JP 6607575B2
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- alumina
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- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 title claims description 69
- 239000011362 coarse particle Substances 0.000 claims description 70
- 239000002245 particle Substances 0.000 claims description 54
- 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 claims description 29
- 229910052863 mullite Inorganic materials 0.000 claims description 29
- 239000011159 matrix material Substances 0.000 claims description 27
- 229910004298 SiO 2 Inorganic materials 0.000 claims description 24
- 239000000203 mixture Substances 0.000 claims description 24
- 229910018072 Al 2 O 3 Inorganic materials 0.000 claims description 21
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 claims description 17
- 238000009826 distribution Methods 0.000 claims description 12
- 229910010413 TiO 2 Inorganic materials 0.000 claims description 11
- 229910052596 spinel Inorganic materials 0.000 claims description 10
- 239000011029 spinel Substances 0.000 claims description 10
- 239000011148 porous material Substances 0.000 claims description 8
- QSHDDOUJBYECFT-UHFFFAOYSA-N mercury Chemical compound [Hg] QSHDDOUJBYECFT-UHFFFAOYSA-N 0.000 claims description 6
- 229910052753 mercury Inorganic materials 0.000 claims description 6
- 238000010304 firing Methods 0.000 claims description 5
- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 claims description 4
- 239000013078 crystal Substances 0.000 claims description 4
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 claims description 4
- 239000000919 ceramic Substances 0.000 claims description 3
- 229910021529 ammonia Inorganic materials 0.000 claims description 2
- 239000011521 glass Substances 0.000 claims description 2
- 238000002407 reforming Methods 0.000 claims description 2
- 239000011734 sodium Substances 0.000 description 47
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 17
- 238000005245 sintering Methods 0.000 description 14
- 239000007789 gas Substances 0.000 description 10
- XEEYBQQBJWHFJM-UHFFFAOYSA-N iron Substances [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 10
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 10
- 238000004519 manufacturing process Methods 0.000 description 10
- 239000000654 additive Substances 0.000 description 9
- 239000010419 fine particle Substances 0.000 description 8
- 230000035939 shock Effects 0.000 description 8
- 239000000377 silicon dioxide Substances 0.000 description 8
- CDBYLPFSWZWCQE-UHFFFAOYSA-L Sodium Carbonate Chemical compound [Na+].[Na+].[O-]C([O-])=O CDBYLPFSWZWCQE-UHFFFAOYSA-L 0.000 description 6
- 230000007797 corrosion Effects 0.000 description 6
- 238000005260 corrosion Methods 0.000 description 6
- 238000000034 method Methods 0.000 description 6
- 239000011882 ultra-fine particle Substances 0.000 description 6
- 238000005452 bending Methods 0.000 description 5
- 239000011449 brick Substances 0.000 description 5
- 230000000052 comparative effect Effects 0.000 description 5
- 239000000843 powder Substances 0.000 description 5
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N Iron oxide Chemical compound [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 4
- 239000011230 binding agent Substances 0.000 description 4
- 239000012535 impurity Substances 0.000 description 4
- 238000000465 moulding Methods 0.000 description 4
- 230000003647 oxidation Effects 0.000 description 4
- 238000007254 oxidation reaction Methods 0.000 description 4
- 229910052708 sodium Inorganic materials 0.000 description 4
- 230000000930 thermomechanical effect Effects 0.000 description 4
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 4
- 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 3
- 229910052784 alkaline earth metal Inorganic materials 0.000 description 3
- 239000004568 cement Substances 0.000 description 3
- 238000002485 combustion reaction Methods 0.000 description 3
- 229910052593 corundum Inorganic materials 0.000 description 3
- 239000010431 corundum Substances 0.000 description 3
- 238000001035 drying Methods 0.000 description 3
- 238000010438 heat treatment Methods 0.000 description 3
- 238000009616 inductively coupled plasma Methods 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- 238000002844 melting Methods 0.000 description 3
- 230000008018 melting Effects 0.000 description 3
- 238000003825 pressing Methods 0.000 description 3
- 239000002994 raw material Substances 0.000 description 3
- 239000000126 substance Substances 0.000 description 3
- NBIIXXVUZAFLBC-UHFFFAOYSA-N Phosphoric acid Chemical compound OP(O)(O)=O NBIIXXVUZAFLBC-UHFFFAOYSA-N 0.000 description 2
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 2
- 230000000996 additive effect Effects 0.000 description 2
- 229910052783 alkali metal Inorganic materials 0.000 description 2
- 150000001340 alkali metals Chemical class 0.000 description 2
- 150000001342 alkaline earth metals Chemical class 0.000 description 2
- 229910052782 aluminium Inorganic materials 0.000 description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 2
- 229910001570 bauxite Inorganic materials 0.000 description 2
- 238000006243 chemical reaction Methods 0.000 description 2
- 239000004927 clay Substances 0.000 description 2
- 238000007596 consolidation process Methods 0.000 description 2
- 238000011065 in-situ storage Methods 0.000 description 2
- 229910052742 iron Inorganic materials 0.000 description 2
- HQKMJHAJHXVSDF-UHFFFAOYSA-L magnesium stearate Chemical compound [Mg+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O HQKMJHAJHXVSDF-UHFFFAOYSA-L 0.000 description 2
- 238000005259 measurement Methods 0.000 description 2
- 230000001590 oxidative effect Effects 0.000 description 2
- 238000013001 point bending Methods 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 238000004611 spectroscopical analysis Methods 0.000 description 2
- 238000004876 x-ray fluorescence Methods 0.000 description 2
- -1 CaO aluminate Chemical class 0.000 description 1
- 229920002134 Carboxymethyl cellulose Polymers 0.000 description 1
- 239000004375 Dextrin Substances 0.000 description 1
- 229920001353 Dextrin Polymers 0.000 description 1
- 241000588731 Hafnia Species 0.000 description 1
- 229910020068 MgAl Inorganic materials 0.000 description 1
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 description 1
- 229920000388 Polyphosphate Polymers 0.000 description 1
- 239000004372 Polyvinyl alcohol Substances 0.000 description 1
- 238000004220 aggregation Methods 0.000 description 1
- 230000002776 aggregation Effects 0.000 description 1
- 239000003513 alkali Substances 0.000 description 1
- ILRRQNADMUWWFW-UHFFFAOYSA-K aluminium phosphate Chemical compound O1[Al]2OP1(=O)O2 ILRRQNADMUWWFW-UHFFFAOYSA-K 0.000 description 1
- 229910000147 aluminium phosphate Inorganic materials 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- 230000001174 ascending effect Effects 0.000 description 1
- 238000001354 calcination Methods 0.000 description 1
- CJZGTCYPCWQAJB-UHFFFAOYSA-L calcium stearate Chemical compound [Ca+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O CJZGTCYPCWQAJB-UHFFFAOYSA-L 0.000 description 1
- 235000013539 calcium stearate Nutrition 0.000 description 1
- 239000008116 calcium stearate Substances 0.000 description 1
- 239000001768 carboxy methyl cellulose Substances 0.000 description 1
- 235000010948 carboxy methyl cellulose Nutrition 0.000 description 1
- 239000008112 carboxymethyl-cellulose Substances 0.000 description 1
- 239000003054 catalyst Substances 0.000 description 1
- 239000001913 cellulose Substances 0.000 description 1
- 229920002678 cellulose Polymers 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 239000000567 combustion gas Substances 0.000 description 1
- 238000004320 controlled atmosphere Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 230000001186 cumulative effect Effects 0.000 description 1
- 238000000354 decomposition reaction Methods 0.000 description 1
- 230000001627 detrimental effect Effects 0.000 description 1
- 235000019425 dextrin Nutrition 0.000 description 1
- 238000010494 dissociation reaction Methods 0.000 description 1
- 230000005593 dissociations Effects 0.000 description 1
- 238000004993 emission spectroscopy Methods 0.000 description 1
- 230000003628 erosive effect Effects 0.000 description 1
- 229910000449 hafnium oxide Inorganic materials 0.000 description 1
- WIHZLLGSGQNAGK-UHFFFAOYSA-N hafnium(4+);oxygen(2-) Chemical compound [O-2].[O-2].[Hf+4] WIHZLLGSGQNAGK-UHFFFAOYSA-N 0.000 description 1
- CJNBYAVZURUTKZ-UHFFFAOYSA-N hafnium(IV) oxide Inorganic materials O=[Hf]=O CJNBYAVZURUTKZ-UHFFFAOYSA-N 0.000 description 1
- 229920005610 lignin Polymers 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 238000011068 loading method Methods 0.000 description 1
- VTHJTEIRLNZDEV-UHFFFAOYSA-L magnesium dihydroxide Chemical compound [OH-].[OH-].[Mg+2] VTHJTEIRLNZDEV-UHFFFAOYSA-L 0.000 description 1
- 239000000347 magnesium hydroxide Substances 0.000 description 1
- 229910001862 magnesium hydroxide Inorganic materials 0.000 description 1
- 235000019359 magnesium stearate Nutrition 0.000 description 1
- 150000002734 metacrylic acid derivatives Chemical class 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 238000007415 particle size distribution analysis Methods 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 239000001205 polyphosphate Substances 0.000 description 1
- 235000011176 polyphosphates Nutrition 0.000 description 1
- 229920002451 polyvinyl alcohol Polymers 0.000 description 1
- 235000019422 polyvinyl alcohol Nutrition 0.000 description 1
- 238000002459 porosimetry Methods 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 238000000746 purification Methods 0.000 description 1
- 238000010791 quenching Methods 0.000 description 1
- 229910052761 rare earth metal Inorganic materials 0.000 description 1
- 239000011819 refractory material Substances 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 239000005368 silicate glass Substances 0.000 description 1
- 150000004760 silicates Chemical class 0.000 description 1
- 238000005382 thermal cycling Methods 0.000 description 1
- 239000004408 titanium dioxide Substances 0.000 description 1
- 229910052845 zircon Inorganic materials 0.000 description 1
- GFQYVLUOOAAOGM-UHFFFAOYSA-N zirconium(iv) silicate Chemical compound [Zr+4].[O-][Si]([O-])([O-])[O-] GFQYVLUOOAAOGM-UHFFFAOYSA-N 0.000 description 1
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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
- C04B35/10—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 aluminium oxide
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- B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
- B01J19/02—Apparatus characterised by being constructed of material selected for its chemically-resistant properties
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- C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
- C01B3/00—Hydrogen; Gaseous mixtures containing hydrogen; Separation of hydrogen from mixtures containing it; Purification of hydrogen
- C01B3/02—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen
- C01B3/025—Preparation or purification of gas mixtures for ammonia synthesis
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- C04B35/101—Refractories from grain sized mixtures
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- C04B35/16—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 silicates other than clay
- C04B35/18—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 silicates other than clay rich in aluminium oxide
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- 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
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- F23M—CASINGS, LININGS, WALLS OR DOORS SPECIALLY ADAPTED FOR COMBUSTION CHAMBERS, e.g. FIREBRIDGES; DEVICES FOR DEFLECTING AIR, FLAMES OR COMBUSTION PRODUCTS IN COMBUSTION CHAMBERS; SAFETY ARRANGEMENTS SPECIALLY ADAPTED FOR COMBUSTION APPARATUS; DETAILS OF COMBUSTION CHAMBERS, NOT OTHERWISE PROVIDED FOR
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- F23R—GENERATING COMBUSTION PRODUCTS OF HIGH PRESSURE OR HIGH VELOCITY, e.g. GAS-TURBINE COMBUSTION CHAMBERS
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- F23R3/00—Continuous combustion chambers using liquid or gaseous fuel
- F23R3/007—Continuous combustion chambers using liquid or gaseous fuel constructed mainly of ceramic components
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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
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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
- C04B2235/3217—Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina
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Description
Al2O3>80%、
SiO2<15%、
Na2O<0.15%、
Fe2O3<0.05%、
CaO<0.1%、
100%までの残りを構成する他の酸化物、すなわち、Al2O3、SiO2、Na2O、K2O、Fe2O3、およびCaO以外の酸化物
であるところの組成を有し、該マトリックス中のNa2Oの含量は、該製品の重量に基づく重量百分率として0.010%超である。
本発明の他の態様によれば、この目的は、ブロックの形状を有し、かつ下記:
100μm超のサイズを有し、粗粒子の集合体を構成する粗粒子、および
上記粗粒子を結合し、かつ100μm以下のサイズを有する粒子からなるマトリックス
からなる焼結耐火製品であって、
該粗粒子の集合体は、該製品の45重量%〜90重量%を占め、
上記製品は、酸化物に基づく重量百分率として、
Al 2 O 3 >80%、
0≦SiO 2 <15%、
0≦Na 2 O<0.15%、
0≦Fe 2 O 3 <0.05%、
0≦CaO<0.1%、
100%までの残りを構成する他の酸化物
であるところの組成を有し、
該マトリックス中のNa 2 Oの含量は、該製品の重量に基づく重量百分率として0.010%超であり、
ムライトの量が、結晶相の重量に基づく重量百分率として、10%超かつ50%未満である。
組成が、Na2O+K2O<0.20%であるところのものである;
組成が、
Al2O3>85%、および/または
3%<SiO2<10%、および/または
Na2O+K2O<0.15%、および/または
Fe2O3<0.03%、および/または
CaO<0.05%、および/または
ZrO2<5%、および/または
TiO2<5%
であるところのものである;
組成が、
Al2O3>90%、および/または
SiO2>7%、および/または
Na2O<0.12%、および/または
ZrO2<1%、および/または
TiO2<1%
であるところのものである;
アルミナの粗粒子の集合体中のNa2Oの含量が、該粗粒子の集合体の重量に基づく重量百分率として0.070%未満である;
アルミナと、ムライトおよび/またはスピネルおよび/またはジルコニアとの合計量が、結晶相の重量に基づく重量百分率として95%超である;
ムライトの量が、該結晶相の重量に基づく重量百分率として10%超かつ50%未満である;
開放空隙率(open porosity)が、10体積%超かつ30体積%未満、好ましくは25体積%未満、20体積%未満;19体積%未満である;
水銀ポロシメータを使用して測定された孔径分布が、
P50が、1μm超かつ20μm未満である、および/または
P80が、10μm超かつ50μm未満である、および/または
P90が、30μm超かつ70μm未満である
ところのものである;
粗粒子の集合体の90重量%超が、ムライトの粗粒子および/またはアルミナの粗粒子および/またはスピネルの粗粒子および/またはムライト−ジルコニアの粗粒子からなる;
マトリックスの90重量%超がアルミナからなる;
100μm以下かつ10μm超のサイズを有する粒子が、製品の重量の10%超かつ30%未満を占め、および/または10μm以下のサイズを有する粒子が、製品の重量の10%超かつ30%未満を占める。
本発明の他の態様による製品はまた、以下の任意的な特徴の1つまたは複数を有しうる。
組成が、0≦Na 2 O+K 2 O<0.20%であるところのものである;
組成が、
Al 2 O 3 >85%、および/または
3%<SiO 2 <10%、および/または
0≦Na 2 O+K 2 O<0.15%、および/または
0≦Fe 2 O 3 <0.03%、および/または
0≦CaO<0.05%、および/または
0≦ZrO 2 <5%、および/または
0≦TiO 2 <5%
であるところのものである;
組成が、
Al 2 O 3 >90%、および/または
SiO 2 >7%、および/または
0≦Na 2 O<0.12%、および/または
0≦ZrO 2 <1%、および/または
0≦TiO 2 <1%
であるところのものである;
該粗粒子の集合体はアルミナの粗粒子の集合体を含み、アルミナの粗粒子の集合体中のNa 2 Oの含量が、該粗粒子の集合体の重量に基づく重量百分率として0.070%未満である;
アルミナと、ムライトおよび/またはスピネルおよび/またはジルコニアとの合計量が、結晶相の重量に基づく重量百分率として95%超である;
ムライトの量が、該結晶相の重量に基づく重量百分率として10%超かつ50%未満である;
開放空隙率(open porosity)が、10体積%超かつ30体積%未満、好ましくは25体積%未満、20体積%未満;19体積%未満である;
水銀ポロシメータを使用して測定された孔径分布が、
P 50 が、1μm超かつ20μm未満である、および/または
P 80 が、10μm超かつ50μm未満である、および/または
P 90 が、30μm超かつ70μm未満である
ところのものである;
該粗粒子の集合体の90重量%超が、ムライトの粗粒子および/またはアルミナの粗粒子および/またはスピネルの粗粒子および/またはムライト−ジルコニアの粗粒子からなる;
マトリックスの90重量%超がアルミナからなる;
100μm以下かつ10μm超のサイズを有する粒子が、製品の重量の10%超かつ30%未満を占め、および/または10μm以下のサイズを有する粒子が、製品の重量の10%超かつ30%未満を占める。
a)本発明による製品の製造に適した供給原料の調製;
b)型に上記供給原料を流し込み、そしてプリフォームを形成するように上記供給原料を圧縮する工程;
c)該型から該プリフォームを取り出す工程;
d)上記プリフォームを乾燥させる工程;
e)上記プリフォームを焼結する工程
を含む方法に関する。
「ブロック」は、粒子でない固形物を意味すると理解される。これは特に、れんが、特に耐火プレートまたは耐火タイルでありうる。
製品は、特にブロックの形態であり得、特にプレートまたはタイルの形態でありうる。好ましくはブロックの厚さは、60mm未満、50mm未満、40mm未満、さらには30mm未満、および/または10mm超、好ましくは15mm超である。好ましくは、ブロックの長さおよび/または幅は、10cm超、20cm超、および/または50cm未満、好ましくは40cm未満である。
好ましくは、酸化物は、製品の重量の90%超、95%超、99%超、さらには実質的に100%を占める。
80%<Al2O3<95%、
2%<SiO2<15%、
0.01%<Fe2O3<0.05%、
0.05%<Na2O+K2O<0.20%、ただし0.03%<Na2O<0.15%、
CaO<0.1%、
100%までの残りを構成する他の酸化物
である。
本発明による製品のマイクロプローブ分析は、マトリックスが、0.15%超の全Na2O含量を有する製品よりもナトリウムに富んでいないことを示す。理論によってそれを説明することができることなしに、ナトリウムは、焼成または焼結中に、ムライトと相互作用することなく、板状アルミナ粒子からマトリックスに拡散すると思われる。
P50が、1μm超、5μm超、10μm超、および/または20μm未満、15μm未満、好ましくは10〜20μmである、および/または
P80が、10μm超、20μm超、25μm超、および/または50μm未満、40μm未満、もしくはさらには35μm未満である、および/または
P90が、30μm超、40μm超、45μm超、および/または70μm未満、60μm未満、もしくはさらには55μm未満である
ところのものである。
45%超の粗粒子の集合体の量の存在は、有利なことに熱衝撃耐性を改善する。
好ましくは、粗粒子の集合体の90重量%超、95重量%超、さらには実質的に100重量%が、ムライト(およそ72〜80%のAl2O3/20〜28%のSiO2)の粗粒子および/または実質的に純粋なアルミナ(>99.5%のAl2O3)、特に板状アルミナの粗粒子、および/またはスピネルの粗粒子および/またはムライト−ジルコニアの粗粒子からなる。
好ましくは、粗粒子の集合体のパーセンタイルD90は、5mm未満、好ましくは3mm未満、好ましくは2mm未満、好ましくは1mm未満、および/または0.2mm超、好ましくは0.3mm超、好ましくは0.4mm超である。
組成
マトリックスは好ましくは、90重量%超、95重量%超、またはさらには実質的に100重量%のアルミナ、好ましくは板状および/またはか焼アルミナからなる。好ましくは、マトリックスは、実質的にシリカを含まない。
100μm以下、かつ10μm超のサイズを有する粒子は、製品の重量の好ましくは10%超、15%超、および/または25%未満、20%未満を占める。
工程a)〜e)は、焼結製品の製造に慣例的に使用される工程である。
10%超、好ましくは20%超、および/または35%未満、30%未満、さらには25%未満のか焼アルミナおよび/または反応性アルミナ、および/または
30%超、35%超、40%超、および/または55%未満、50%未満、さらには45%未満の板状アルミナ
を含む。
板状アルミナの粗粒子、さらには粗粒子のすべては、供給原料の酸化物に基づく重量百分率として、1500ppm未満、好ましくは1000ppm未満、好ましくは500ppm未満の重量含量のNa2O+K2O、好ましくはNa2Oを有する。この理論によって束縛されることなく、本発明者らは、この低い含量は、不利となる相をもたらす反応を防止すると考える。
10%超、15%超、20%超、および/または45%未満、35%未満、30%未満、さらには25%未満のアルミナ粒子、好ましくは板状アルミナ粒子、および/または
1%超、好ましくは5%超、15%超、25%超、30%超、および/または45%未満、40%未満のムライト粒子
を含む。
微粒子画分は、好ましくは、供給原料の酸化物に基づく重量百分率として、1%超、5%超、10%超、15%超、および/または25%未満、20%未満の板状アルミナ粒子を含み、上記粒子は、好ましくは10μm超かつ100μm未満のサイズを有する。
供給原料はまた、成形工程b)中に十分な可塑性を供給原料に与え、そしてプリフォームに十分な機械的強度を付与するために慣例的に使用される、任意的に粒状形態であってもよい、1種または複数の添加剤を含有しうる。添加剤の量は、限定的でない。特に、公知の焼結方法において慣例的に使用される量が適する。しかし添加剤は、これらの組成、特にアルカリ金属およびアルカリ土類金属の含量が本発明による耐火製品の製造に適合するように選択される。
一時的な(すなわち、乾燥および焼成工程中に完全にまたは部分的に除去される)有機結合剤、例えば、樹脂、セルロースまたはリグニンの誘導体、例えば、カルボキシメチルセルロースおよびデキストリン、ならびにポリビニルアルコールなど、ここで好ましくは、一時的な結合剤の量は、供給原料の酸化物の粒状混合物の重量に対して0.1重量%〜6重量%である;
化学的結合剤、例えば、リン酸または一リン酸アルミニウム;
水硬性結合剤、例えば、アルミニウム含有(aliminous)セメント、例えば、SECAR71セメント、またはCaOアルミネートタイプのセメント;
解膠剤、例えば、アルカリ金属ポリホスフェートまたはメタクリレート誘導体;
焼結促進剤、例えば、二酸化チタン(供給原料の重量のおよそ2%を超えない割合で)または水酸化マグネシウム;
成形剤、例えば、ステアリン酸マグネシウムまたはステアリン酸カルシウム;
天然シリコ−アルミネートタイプ、例えば、粘土、または合成シリコ−アルミネートの添加物、ここで、これらの添加剤、特に天然粘土は、アルミナ、シリカ、およびいくつかのアルカリ金属もしくはアルカリ土類金属酸化物、または酸化鉄すらを導入しうる。
ガスタービンの側壁は慣例的に、組み立てられるところの複数のブロックを、好ましくはタイルの形態で含む。
Claims (13)
- ブロックの形状を有し、かつ下記:
100μm超のサイズを有し、かつ粗粒子の集合体を構成する粗粒子、および
上記粗粒子を結合し、かつ100μm以下のサイズを有する粒子からなるマトリックス
からなる焼結耐火製品であって、
該粗粒子の集合体は、該製品の45重量%〜90重量%を占め、
上記製品は、酸化物に基づく重量百分率として、
Al2O3>80%、
2%<SiO2<15%、
0%<Na2O<0.15%、
0%≦Fe2O3<0.05%、
0%≦CaO<0.1%、
100%までの残りを構成する他の酸化物
であるところの組成を有し、
該マトリックス中のNa2Oの含量は、該製品の重量に基づく重量百分率として0.010%超であり、
ムライトの量が、結晶相の重量に基づく重量百分率として、10%超かつ50%未満である、
上記焼結耐火製品。 - 0%≦Na2O+K2O<0.20%である、請求項1に記載の製品。
- Al2O3>85%、および/または
3%<SiO2<10%、および/または
0%≦Na2O+K2O<0.15%、および/または
0%≦Fe2O3<0.03%、および/または
0%≦CaO<0.05%、および/または
0%≦ZrO2<5%、および/または
0%≦TiO2<5%
である、請求項1または2に記載の製品。 - Al2O3>90%、および/または
SiO2>7%、および/または
0%≦Na2O<0.12%、および/または
0%≦ZrO2<1%、および/または
0%≦TiO2<1%
である、請求項1〜3のいずれか一項に記載の製品。 - 該粗粒子の集合体はアルミナの粗粒子の集合体を含み、該アルミナの粗粒子の集合体中のNa2Oの含量が、該粗粒子の集合体の重量に基づく重量百分率として0.070%未満である、請求項1〜4のいずれか一項に記載の製品。
- アルミナと、ムライトと、スピネルが存在する場合にはスピネルと、ジルコニアが存在する場合にはジルコニアと、の合計量が、結晶相の重量に基づく重量百分率として95%超である、請求項1〜5のいずれか一項に記載の製品。
- 10体積%超かつ30体積%未満の開放空隙率を有する、請求項1〜6のいずれか一項に記載の製品。
- 20体積%未満の開放空隙率を有する、請求項1〜7のいずれか一項に記載の製品。
- 水銀ポロシメータを使用して測定された孔径分布が、
P50が1μm超かつ20μm未満である、および/または
P80が10μm超かつ50μm未満である、および/または
P90が30μm超かつ70μm未満である、
請求項1〜8のいずれか一項に記載の製品。 - ムライトの粗粒子、アルミナの粗粒子、スピネルの粗粒子およびムライト−ジルコニアの粗粒子のそれぞれの量(ゼロでもよい)の合計が該集合体の重量の90重量%超である、請求項1〜9のいずれか一項に記載の製品。
- 該マトリックスの90重量%超がアルミナからなる、請求項1〜10のいずれか一項に記載の製品。
- 100μm以下かつ10μm超のサイズを有する粒子が、該製品の重量の10%超かつ30%未満を占め、および/または10μm以下のサイズを有する粒子が、該製品の重量の10%超かつ30%未満を占める、請求項1〜11のいずれか一項に記載の製品。
- ガスタービン、セラミック部品用の焼成支持体、アンモニアまたはメタンを製造するための二次改質反応器、およびガラス炉上部構造によって形成される群から選択されるデバイスであって、請求項1〜12のいずれか一項に記載の製品によって少なくとも部分的に形成された1つの壁を含む、上記デバイス。
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CA3057147A1 (en) * | 2017-04-17 | 2018-10-25 | Vesuvius Usa Corporation | Porous refractory cast material, its use and production |
EP3453689B1 (en) * | 2017-09-08 | 2020-08-26 | AGC Ceramics Co., Ltd. | High-zirconia electrocast refractory and method for manufacturing the same |
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JP7062087B2 (ja) | 2018-12-06 | 2022-05-02 | 日本碍子株式会社 | セラミックス焼結体及び半導体装置用基板 |
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JP7054683B2 (ja) * | 2019-02-28 | 2022-04-14 | サンゴバン・ティーエム株式会社 | 高アルミナ質溶融鋳造耐火物及びその製造方法 |
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JPH06122547A (ja) * | 1992-10-13 | 1994-05-06 | Toshiba Ceramics Co Ltd | 製鋼用耐火れんが |
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US9908816B2 (en) * | 2010-04-28 | 2018-03-06 | Saint-Gobain Centre De Recherches Et D'etudes Europeen | Refractory powder comprising coated mullite grains |
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