WO2013147080A1 - 不定形耐火物の気流搬送式吹付け施工法 - Google Patents
不定形耐火物の気流搬送式吹付け施工法 Download PDFInfo
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- WO2013147080A1 WO2013147080A1 PCT/JP2013/059373 JP2013059373W WO2013147080A1 WO 2013147080 A1 WO2013147080 A1 WO 2013147080A1 JP 2013059373 W JP2013059373 W JP 2013059373W WO 2013147080 A1 WO2013147080 A1 WO 2013147080A1
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D1/00—Casings; Linings; Walls; Roofs
- F27D1/0003—Linings or walls
- F27D1/0006—Linings or walls formed from bricks or layers with a particular composition or specific characteristics
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
- C04B28/06—Aluminous cements
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/66—Monolithic refractories or refractory mortars, including those whether or not containing clay
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D1/00—Casings; Linings; Walls; Roofs
- F27D1/16—Making or repairing linings increasing the durability of linings or breaking away linings
- F27D1/1636—Repairing linings by projecting or spraying refractory materials on the lining
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/00034—Physico-chemical characteristics of the mixtures
- C04B2111/00146—Sprayable or pumpable mixtures
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/20—Resistance against chemical, physical or biological attack
- C04B2111/28—Fire resistance, i.e. materials resistant to accidental fires or high temperatures
Definitions
- the present invention relates to an airflow conveying type spraying method for an amorphous refractory, and in particular, suppresses a change in properties of the amorphous refractory material, and sprays the amorphous refractory stably with simple operation.
- the present invention relates to an air current conveying type spraying construction method capable of performing construction.
- the spraying construction method is known as an effective construction method for irregular refractories. Compared with the casting method, this construction method does not require a casting mold, and can be easily applied to places where the shape is complicated and the framework is difficult, so it is widely used in more and more fields in recent years. ing.
- Such spraying methods can be broadly classified into a wet pumping method using a pumping method and a dry spraying method using a pneumatic method.
- the wet spraying construction method is a construction method in which spraying is performed after preparing a kneaded material called “kneaded clay” in which a refractory composition for spraying and construction water are sufficiently kneaded in advance.
- the kneaded material is kneaded until a fluid flow value (using JIS cone) that can be pumped using a mixer reaches about 200 mm, and this is fed to the pump and transported through the transport pipe.
- a quick setting agent for agglomerating the clay at the nozzle and supplying compressed air it sprays on the construction object and agglomerates relatively instantaneously to construct a refractory such as a furnace wall. To do.
- a refractory having a uniform quality and excellent physical properties can be obtained, but when supplying the spraying material to the pressure feed pump as described above, sufficient fluidity is obtained using a mixer. Since it is necessary to knead the spray material, a large mixer and a large number of personnel are required. Moreover, since it pumps with a pump, management of the amount of kneading
- the wet spray construction method has many unstable elements during construction on site.
- the transport distance is shorter than that of the dry spraying method.
- the distance is about 100m at most.
- the wet spraying method using a pump when the construction is completed, the kneaded clay remains in the transfer pipe, so there is a problem that a lot of material is lost and that it takes a lot of people and time to take out and clean it. .
- the dry spraying method is for powdery spraying that contains a hardener such as alumina cement that hardens when combined with water, and refractory powder such as clay to improve adhesion during spraying.
- Refractory material is supplied to a pneumatic feeding sprayer and pneumatically fed through the transfer pipe.
- Construction water is added to the powdered refractory material for spraying by the spray nozzle, and the construction water is added to the powdered refractory composition for spraying to create a highly viscous adhesive state. Is blown out through the nozzle, adheres and hardens to the construction object, and builds a refractory.
- the spraying refractory composition is pneumatically fed in powder form, so that the transportation pipe is not clogged, so that transportation is easy and long distance transportation is possible. Therefore, this method has the advantage that it can be installed at a distant place or a high place with a spraying machine or a fireproofing composition for spraying installed on the ground, and it can be applied to various work sites. Applicable.
- the dry spray construction method mixes the powdered amorphous refractory composition and construction water in the nozzle to create a viscous adhesion state, so the contact time of the refractory composition and construction water is short. .
- the amount of refractory composition fed pneumatically is not constant, the amount of construction water to be added must also be changed accordingly, the operator's adjustment of the amount of water will not catch up, and the amount of construction water will also vary In some cases, the construction water does not reach the specified amount or the mixing is not sufficiently uniform, so the quality of the constructed refractory furnace wall becomes non-uniform, resulting in a stable and high-quality refractory with high strength. It tends to be difficult to obtain.
- the material and quick setting agent used in the wet spraying method are used, but the material is pneumatically conveyed to the vicinity of the nozzle in the form of powder without forming a clay with a mixer in advance. After adding construction water on the upstream side, it is transported as it is and sprayed onto the construction object, and it is agglomerated in a relatively short time to build a refractory material (hereinafter referred to as dry spraying construction method). In order to distinguish from this, this construction method is referred to as an air current conveying type spraying construction method).
- the powder material and construction water are mixed in the conveying pipe after the addition of water, so that a large mixer, a pressure pump and a large number of personnel are not required. Moreover, since it is conveyed with powder in the conveying pipe, it is possible to construct at a long distance and at a high place.
- the air current transfer spraying method is an external addition method in which the construction water is added upstream of the nozzle, and then the air transfer is continued and the quick setting agent is added near the nozzle.
- Patent Documents 1 and 2 Japanese Patent Documents 1 and 2
- Patent Document 3 an internal addition method in which a powder quick-setting agent is added and mixed in advance during the production of an irregular refractory composition. It has been.
- Japanese Unexamined Patent Publication No. 10-316478 Japanese Unexamined Patent Publication No. 2000-356475 Japanese Unexamined Patent Publication No. 2002-213880
- the external addition method conveys the powder accelerating agent to the vicinity of the nozzle and adds the powder accelerating agent at a pressure higher than the pressure in the conveying pipe being pneumatically fed. It is necessary to add pressure. For this reason, a quick setting agent supply device, a quick setting agent transport pipe, a quick setting agent addition unit, etc. are required, and the device configuration is complicated. In particular, a special device that can supply the quick setting agent at high pressure is essential. It was. In addition, since the addition position of the powder quick-setting agent is in the vicinity of the nozzle as described above, the installer who operates the nozzle on the construction object transports the quick-setting agent in addition to the construction water transport pipe and the addition section. A tube and an addition part were added, and the work burden was remarkably increased.
- the powder accelerating agent is already mixed in the irregular refractory composition at the manufacturing stage, there is no problem in apparatus configuration and operation as in the external addition method.
- the powder quick-setting agent is included in the material, in order to construct a stable refractory material, such as limiting the storage period until use (construction) and avoiding storage at high temperature and high humidity, It has been newly found by the present inventors that care may be required. In other words, in storage over a long period of time or in a high temperature and high humidity environment, it is possible to obtain a decrease in workability such as dust generation during construction and an increase in rebound loss due to changes in the characteristics of the quick setting agent. It has been found that the quality of the refractory may be impaired.
- the present invention is a troublesome storage and storage management of the irregular refractory material, which is a weak point of the internal addition method, in the above-described air current conveying type spraying construction method, while having a simple device configuration equivalent to the internal addition method.
- the purpose is to provide a method for spraying irregular refractories that can eliminate the problem and maintain the original quality of the material.
- the non-standard refractory air-conveying spraying method is applied to an amorphous refractory material containing a refractory aggregate, a refractory powder, a binder, and a dispersant, immediately before the air-flow conveyance.
- Addition and mixing to form an amorphous refractory composition and the amorphous refractory composition is put in an air stream in a powder state and fed from one end side of the transport pipe into the transport pipe and transported to the other end side.
- An airflow conveying step, a construction water addition step of adding construction water to the amorphous refractory composition being conveyed in the airflow conveying step, and an amorphous refractory composition to which the construction water is added are applied from a spray nozzle. And a spraying step of spraying on the object.
- the powder rapid setting agent is added just before the airflow conveyance so that the trouble of conveying the powder rapid curing agent to the vicinity of the nozzle is also conveyed.
- No complicated equipment configuration for supplying high pressure into the pipe is required, and since it is not mixed with the powder quick-setting agent until just before use, troublesome material storage management becomes unnecessary, and the obtained refractory characteristics can be stabilized. .
- FIG. 1 is a diagram for explaining an airflow conveying type spray construction method for an irregular refractory according to an embodiment of the present invention.
- this spray construction device 1 includes an air current transport device 2, a transport pipe 3, a construction water addition means 4, a construction water addition unit 5, a spray nozzle 6, and a quantitative transport device. 7, a quick setting agent supply machine 8, and a compressor 9.
- the air current conveying machine 2 conveys the amorphous refractory composition 22 at a predetermined solid / gas ratio using the compressed air of the compressor 9 so that the amorphous refractory composition 22 can be conveyed in a powder state.
- the unshaped refractory composition 22 fed into the interior 3 is transported from one end side (airflow transporter 2 side) of the transport pipe 3 to the other end side (spraying nozzle 6 side).
- the supply amount of the amorphous refractory composition 22 per unit time and the amount of gas to be blown are made constant, and the predetermined amount (solid / gas ratio) of the amorphous refractory composition is always provided. It is preferable that the article 22 is transported in the transport pipe 3.
- This solid / gas ratio is a volume ratio, usually 1/200 to 1/400.
- the conveyance pipe 3 is a passage that conveys the powdered amorphous refractory composition 22 in a powder state by an air flow, and the nozzle 6 sprays the wet amorphous refractory composition even when construction water is added on the way. Can be transported up to. That is, the transport pipe 3 is not limited as long as it can stably transport the powdery and / or wet amorphous refractory composition 22 by connecting the airflow transporter 2 and the spray nozzle 6.
- the transport pipe 3 is preferably a conventionally used metal pipe such as steel or a resin hose made of rubber or polyethylene.
- the inner diameter of the conveying pipe 3 may be appropriately selected depending on the amount of the amorphous refractory composition 22 to be conveyed, the construction site, and the like, and is usually preferably 65 mm or less. If the inner diameter of the conveying pipe exceeds 65 mm, the spraying amount per unit time becomes too large, and if the inner diameter is excessively small, pressure loss occurs.
- the inner diameter of the transfer tube 3 is more preferably 25 to 65 mm.
- the diameter of the transport pipe 3 can be appropriately selected depending on the amount and size of the amorphous refractory composition 22 to be transported, and the ratio of the maximum particle diameter in the amorphous refractory composition 22 to be used / the inner diameter of the transport pipe is It is preferable to set to 1/7 to 1/3.
- a conveying tube having an inner diameter of 38 to 65 mm may be used.
- the length of the transfer pipe 3 is not limited as long as air flow can be stably carried out.
- the transfer pipe 3 can be transferred at a horizontal distance of about 200 m and a height of about 150 m.
- the shape of the transport pipe 3 is made of a flexible material such as resin as described above, because it can be easily arranged and moved in accordance with the situation at the site.
- the conveying pipe 3 of the present invention blows the amorphous refractory composition 22 to the high location, and the spray nozzle 6 can be brought close to the construction object, so that it is stable. Enables construction.
- the construction water addition means 4 adds construction water into the transport pipe 3 in which the powdery amorphous refractory composition 22 is transported to make the amorphous refractory composition 22 wet.
- the amorphous refractory composition 22 in a wet state is transported to the spray nozzle 6 by the force of the airflow generated by the airflow transporter 2.
- the construction water into the conveyance pipe 3 by the construction water addition means 4 is supplied by supplying the construction water sent by the construction water addition means 4 into the conveyance pipe by the construction water addition section 5.
- the construction water addition means 4 is preferably, for example, a metal pipe made of stainless steel or the like, or a resin hose made of rubber or polyethylene.
- the inner diameter of the construction water addition means 4 may be appropriately selected depending on the amount of construction water to be supplied, the situation at the construction site, and the like, and is usually preferably 9 to 25 mm.
- the construction water addition means 4 is connected to a water addition port provided in the middle of the conveyance pipe 3 so that the construction water can be supplied into the conveyance pipe 3, and a construction water addition section 5 is provided.
- the position of the construction water addition part 5 is preferably 0.3 to 15 m from the tip of the spray nozzle 6. If the length is shorter than 0.3 m, the amorphous refractory composition 22 and the construction water may not be sufficiently mixed, and a refractory having sufficient characteristics cannot be constructed. If the length is longer than 15 m, the amorphous refractory composition is formed in the transport pipe 3. There is a possibility that the objects 22 are likely to accumulate, and the amount of spraying is reduced, or the inside of the transport pipe 3 is closed and spraying itself cannot be performed.
- the spray nozzle 6 is attached to the tip of the transport pipe 3 and sprays the unshaped refractory composition 22 to which construction water is added to the construction object.
- a spray nozzle of an amorphous fireproof composition that has been conventionally used may be used.
- Quantitative conveyance machine 7 is capable of quantitatively and continuously supplying amorphous refractory material 20 to airflow conveyance machine 2 at an arbitrary set value.
- Primate II (trade name) manufactured by Nihon Pribrico is available.
- the quick setting agent supply unit 8 is capable of supplying the powder quick setting agent 21 in a predetermined amount and continuously to the amorphous refractory material 20 transported by the fixed amount transporting device 7, and supplying a small amount of powder. Any method can be used as long as it is a machine. For example, a micron feeder (manufactured by Aisin Nano Technologies, trade name), a millifeeder (manufactured by Alpha, trade name) and the like can be mentioned.
- the amorphous refractory material 20 conveyed by the quantitative conveying machine 7 and the powder quick-setting agent 21 supplied by the quick-setting agent supply machine 8 are mixed to become the amorphous refractory composition 22, but are applied.
- the fixed quantity conveying machine 7 may be used, or an independent mixing means is provided so that the amorphous refractory material 20 and the powder quick-setting agent 21 are provided.
- the amorphous refractory composition 22 may be obtained by stirring and mixing.
- the mixing method is not particularly limited as long as the amorphous refractory material 20 and the powder quick-setting agent 21 can be mixed together.
- mixing means When mixing means is provided in the fixed amount transporter 7, when the powder quick-setting agent 21 is added to the amorphous refractory material 20 in the middle of transporting to the airflow transporter 2 and this is supplied to the airflow transporter 2 in a fixed amount.
- This mechanism for example, a screw conveyance type supply mechanism, can be used, and a stirring plate can be easily added to the screw to increase the mixing ability.
- the conveyance supply mechanism of the quantitative conveyance device 7 is not particularly limited as long as it can mix and supply the amorphous refractory material 20 and the powder quick-setting agent 21 to the airflow conveyance device 2.
- the compressor 9 is for supplying compressed gas to the air current conveying machine 2.
- the compressed gas supplied here introduces the amorphous refractory composition 22 supplied from the quantitative conveyance device 7 into the conveyance pipe 3 in the air current conveyance device 2, and the amorphous refractory composition 22 remains in a powder state. It is transported in the transport pipe 3.
- This spray construction method is characterized in that an amorphous refractory composition 22 is obtained by adding and mixing a powder quick-setting agent 21 to the amorphous refractory material 20 at the place of use immediately before airflow conveyance.
- “immediately before the air current conveyance” refers to the period before the air current conveyance and until the amorphous refractory material 20 is supplied to the air current conveyance device 2, and means addition and mixing at the construction site.
- the powder rapid setting agent 21 is added and mixed at a predetermined ratio to the amorphous refractory material 20 being conveyed by the above-described quantitative conveying machine 7. What is necessary is just to prepare a refractory material and a powder quick-setting agent separately, and to mix when starting construction.
- the amorphous refractory composition 22 obtained in this way is transported in the transport pipe 3 in a powder state by the compressed gas sent from the compressor 9 in the airflow transporter 2.
- the airflow transport device 2 is not particularly limited as long as the powder of the amorphous refractory composition 22 can be transported by airflow.
- a spraying device such as a need gun (trade name) manufactured by Nihon Pribrico is used. it can.
- the predetermined amount of the amorphous refractory composition 22 is continuously supplied to the airflow conveyance machine 2, and the compressor 9 is used as the airflow source.
- the conveyance amount of the amorphous refractory composition 22 per hour can be stably quantified.
- the amorphous refractory composition 22 fed into the transport pipe 3 is transported in the direction of the spray nozzle 6 through the transport pipe 3 by the air current generated by the compressed air supplied to the air current transport machine 2.
- the length of the transport pipe 3 is also related to the capability of the airflow transport machine 2, but in the present invention, since it can be transported in powder form, it is characterized in that it can be applied over an extremely long distance.
- a conveying distance that is about 100 m at most in the wet spraying method can be as long as 200 m.
- the construction water is added by the construction water addition means 4 in the middle of the transport pipe 3 to the amorphous refractory composition 22 transported in the transport pipe 3 in this way.
- the position of the construction water addition section 5 to which construction water is actually supplied is preferably 0.3 to 15 m upstream from the tip of the spray nozzle 6, and when the addition of water is performed at a position less than 0.3 m, The amorphous refractory composition 22 and the construction water are not sufficiently mixed, and a refractory having sufficient characteristics may not be constructed.
- the water addition position is more preferably 0.3 to 5 m upstream from the tip of the spray nozzle 6.
- the amount of construction water added to the irregular refractory composition 22 in the present invention is substantially the entire amount of construction water necessary for spraying refractories.
- “substantially” means almost all the required amount, and a small amount of water can optionally be added at other locations.
- a small amount of water may be added to the amorphous refractory composition 22 in order to prevent the powder from rising, so that a so-called premoist state may be obtained.
- the three systems can take various structures, but the wet state of the refractory composition in the transport tube of the present invention
- the so-called “Filament (II) region” (Umeya: Gakken 136 Committee, Academic Refractory Construction Technology Council Study Group data), in which air is confined in continuous particles of water and water, Therefore, it is considered that the amorphous refractory composition 22 in the wet state of the present invention is transported while floating in the transport pipe.
- this is a mechanism estimation and does not constrain the interpretation of the present invention.
- the construction water added here is supplied by the construction water addition means 4 up to the construction water addition unit 5, and the supply source of the construction water is usually arranged in the vicinity of the airflow transporter 2. Therefore, the construction water addition means 4 has the same length as the transport pipe 3.
- the construction water corresponding to a predetermined mixing ratio is added to the powdered amorphous refractory composition 22 to make it wet, and it is transported to the spray nozzle 6 and directly applied to the construction wall 23 that is the construction object. Be sprayed.
- the transfer air is degassed into the outside air by an impact when blown against the construction wall surface 23.
- the sprayed amorphous refractory is degassed and then rapidly agglomerates due to the effect of the quick-setting agent, and then hardens to become the construction refractory 24, and a strong furnace wall is constructed.
- the amorphous refractory material 20 used in the present embodiment is the same as a conventionally used material, for example, a powdery material including a refractory aggregate, a refractory powder, a binder and a dispersant. is there.
- refractory aggregates include alumina, bauxite, diaspore, mullite, kayanite, van earth shale, chamotte, quartzite, pyrophyllite, sillimanite, andalusite, chromite, spinel, magnesia, zirconia, zircon.
- One or more selected from the group consisting of carbon such as chromia, silicon nitride, aluminum nitride, silicon carbide, boron carbide and graphite, titanium boride and zirconium boride are preferred.
- the refractory powder contained in the amorphous refractory material 20 forms a joint for joining the refractory aggregate by filling the gaps of the refractory aggregate, and has an average particle diameter of 150 ⁇ m or less.
- the average particle diameter is preferably 10 ⁇ m or less, and a refractory ultrafine powder of 5 ⁇ m or less is more preferably used.
- alumina, fumed silica and the like are preferable.
- Such alumina and fumed silica may be used in the form of not only powder but also a part of alumina sol, silica sol or colloidal silica.
- the refractory powder is preferably contained in an amount of 30 to 60 parts by weight, particularly 40 to 50 parts by weight, based on 100 parts by weight of the refractory aggregate.
- refractory powder in addition to the above refractory ultrafine powder, other materials having an average particle diameter of 30 ⁇ m or less can be added although the particle size is larger than that of the refractory ultrafine powder.
- materials include alumina, titania, bauxite, diaspore, mullite, van earth shale, chamotte, pyrophyllite, sillimanite, andalusite, quartzite, chromite, spinel, magnesia, zirconia, zircon, chromia, silicon nitride, Amorphous silica such as aluminum nitride, silicon carbide, boron carbide, titanium boride, zirconium boride, bentonite or silica may be mentioned.
- the amorphous refractory composition is a refractory material which is a clay-like material whose viscosity rapidly increases when moisture is added, as contained in the conventional refractory material of the dry construction method.
- Clay, kaolin, bentonite and the like are preferably reduced as much as possible, and preferably 3 parts by mass or less with respect to 100 parts by mass of the refractory aggregate.
- the binder contained in the amorphous refractory material 20 functions as a binder for the amorphous refractory, and preferably, alumina cement is used.
- alumina cement is used as a binder, the construction body can maintain strength in a wide range from room temperature to high temperature.
- phosphates such as phosphoric acid and aluminum phosphate
- silicates such as sodium silicate and potassium silicate, lignin sulfonate, water-soluble phenol and the like can be used.
- the binder is preferably contained in an amount of 2.5 to 20 parts by mass, particularly 5 to 12 parts by mass, with respect to 100 parts by mass of the refractory aggregate.
- the dispersant contained in the amorphous refractory composition is important.
- the viscosity increases when construction water is added to the powdered composition, and the conveying pipe is blocked. There is a risk of it.
- This dispersant is a condensed phosphate such as sodium tetrapolyphosphate and sodium hexametaphosphate, a carboxylate such as polycarboxylate and polyacrylate, a melamine sulfonate, and a sulfone such as ⁇ -naphthalene sulfonate.
- One or more selected from the group consisting of acid salts are preferred.
- the dispersant is preferably added in an amount of 0.03 to 1.5 parts by mass, particularly 0.08 to 0.35 parts by mass, with respect to 100 parts by mass of the refractory aggregate.
- the powder accelerating agent 21 used in the present invention needs to be added to and mixed with an amorphous refractory material under normal pressure before airflow conveyance, and sent into the conveyance pipe at high pressure as in addition during airflow conveyance. Therefore, it is easy to quantitatively supply the amorphous refractory material 20, and a known device capable of quantitative supply may be prepared, and no special device is required.
- the quick setting agent includes silicates such as sodium silicate and potassium silicate, aluminates such as sodium aluminate, potassium aluminate and calcium aluminate, carbonates such as sodium carbonate, potassium carbonate and sodium bicarbonate.
- silicates such as sodium silicate and potassium silicate
- aluminates such as sodium aluminate, potassium aluminate and calcium aluminate
- carbonates such as sodium carbonate, potassium carbonate and sodium bicarbonate.
- sulfates such as magnesium sulfate, CaO ⁇ Al 2 O 3, 12CaO ⁇ 7Al 2 O 3, CaO ⁇ 2Al 2 O 3, 3CaO ⁇ Al 2 O 3, 3CaO ⁇ 3Al 2 O 3 ⁇
- calcium aluminates such as CaF 2 , 11CaO ⁇ 7Al 2 O 3 ⁇ CaF 2
- calcium salts such as calcium oxide, calcium hydroxide, calcium chloride or mixtures thereof are preferable.
- the substance called a known quick setting agent and a flocculant can also be used.
- sodium aluminate Because it is easily available, is inexpensive, and has excellent characteristics. Since sodium aluminate has a high melting point, it does not lower the fire resistance of the refractory and does not impair the properties of the refractory.
- These quick setting agents are in the form of powder and the average particle diameter is preferably 20 to 200 ⁇ m, particularly 50 to 100 ⁇ m.
- the addition amount of the quick setting agent should be 0.05 to 3 parts by mass on the basis of the outer weight and dry basis with respect to 100 parts by mass of the amorphous refractory material excluding additives such as dispersants and retarders. preferable. If the amount is less than 0.05 parts by mass, even if it is a good setting agent, the rapid setting speed may be insufficient and the refractory applied by spraying may flow down. On the other hand, if more than 3 parts by mass are injected, It hardens rapidly, making spraying difficult, and the performance as a refractory such as heat resistance and corrosion resistance decreases. Since the addition amount of the quick setting agent varies depending on the type of the quick setting agent, it is preferable to adjust the injection amount according to the type of the quick setting agent.
- this spray construction method if necessary, by adding 0.002 to 0.2 parts by weight of a retarder as an outer shell to 100 parts by weight of the irregular refractory material, Aggregation time can be controlled and refractory can be sprayed stably.
- a retarder weak acids such as oxalic acid, boric acid, malic acid, citric acid and lignin sulfonate can be preferably used.
- the quick setting agent is added to the irregular refractory material immediately before the construction at the site of the spray construction.
- Stable refractories can be constructed even after long-term storage under various conditions.
- the transport distance from the supply destination to the spraying point is about 100 mm in the horizontal distance and about 60 m in the high place.
- the amorphous refractory composition and the construction water are mixed in the transport pipe, there is no fear of clogging in the transport pipe, and long distance transport of about 200 m or high place up to about 150 m. Made possible.
- the quick-setting agent is also included in the irregular refractory composition, it is not necessary to perform equipment for adding the quick-setting agent in the middle of the transport pipe or to control the setting.
- the cleaning and maintenance work is greatly reduced, and the irregular fire resistance due to the residual in the transport pipe. Material loss was significantly reduced.
- the obtained sprayed refractory has excellent properties that are uniform and large in strength.
- Example 1 Using the irregular refractory spraying construction apparatus 1 shown in FIG. 1 and using the powdery amorphous refractory composition having the composition shown in Table 1 as the irregular refractory composition, Air-flow conveying spray construction was performed.
- content is a numerical value of the mass part per 100 mass parts of amorphous refractory compositions except a dispersing agent and a retarder.
- an amorphous refractory material mixed with refractory aggregate, refractory powder, alumina cement as a binder, a dispersant and a retarder is measured by a quantitative conveying machine 7 (Primate II (trade name) manufactured by Japan Private Co.). It transported to the air current transport device 2 (Need Gun 400 (trade name) manufactured by Japan Private Co.), and a predetermined amount of quick setting agent was added by the quick setting agent supply device 8 to the ratio shown in Table 1 during the transport. .
- the refractory is obtained by the same operation described below for each of the case where it is used immediately after preparation (usually) and the case where it is stored at 30 ° C. for 120 days (after storage). We performed construction of.
- Primate II (trade name) supplies a fixed amount of an amorphous refractory composition to which an accelerating agent is added to the air current carrier 2, but its mechanism is quantitative by a supply mechanism called a screw type auger. Is cut out and supplied. During this supply, the amorphous refractory material and the quick setting agent are mixed almost uniformly.
- tap water construction water
- amorphous refractory composition was added at a position of 0.8 m from the tip of the spray nozzle 6 while conveying the amorphous refractory composition by airflow.
- the wet-shaped amorphous refractory composition to which construction water was added was conveyed to the spray nozzle 6 and sprayed directly onto a spray panel having a length of 400 mm ⁇ width of 400 mm ⁇ thickness of 100 mm.
- the discharge amount of the irregular refractory composition was 2000 kg / hr, and the spraying pressure was 0.3 MPa.
- Comparative Example 1 In Comparative Example 1, the amorphous refractory composition was sprayed by the same configuration and operation as Example 1 except that all materials were mixed in advance as the amorphous refractory composition to be used. That is, after preparing the amorphous refractory composition by mixing all the materials in advance, the spraying construction was performed immediately, and after storing the amorphous refractory composition at 30 ° C. for 120 days, the spraying construction was performed. Two constructions were performed.
- Example 1 In Example 1 and Comparative Example 1, for each case where the material was applied immediately after preparation and when the material was applied after being stored at high temperature, each of the five spray panels was created and allowed to air dry for more than one day. After that, the cut surface of the construction body was observed by cutting in the thickness direction with a cutter, and the bulk density and bending strength of the panel after drying at 110 ° C. were measured. The test results are summarized in Table 2. Showed.
- the method for spraying an irregular refractory according to the present invention can be used for the construction of an irregular refractory by airflow conveying spray. It should be noted that the entire content of the specification, claims, drawings and abstract of Japanese Patent Application No. 2012-080934 filed on March 30, 2012 is cited herein as the disclosure of the specification of the present invention. Incorporated.
- SYMBOLS 1 Amorphous refractory composition spray construction apparatus, 2 ... Airflow conveyance machine, 3 ... Conveyance pipe, 4 ... Construction water addition means, 5 ... Construction water addition part, 6 ... Spray nozzle, 7 ... Fixed quantity conveyance machine, DESCRIPTION OF SYMBOLS 8 ... Quick setting agent supply machine, 9 ... Compressor, 20 ... Amorphous refractory material, 21 ... Powder quick setting agent, 22 ... Amorphous refractory composition, 23 ... Construction wall surface, 24 ... Construction refractory
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Abstract
Description
(1)粉末状の不定形耐火組成物の気流を利用した搬送によるために、大型ミキサーによる吹付け不定形耐火組成物の混練作業を不要とし、また、圧損失の大きい混練物を圧送するポンプの使用も不要である。
(2)従来の湿式吹付け施工法では、不定形耐火組成物を坏土状で搬送するため供給先から吹付け箇所までの搬送距離が水平距離で100mm程度、高所で60m程度が限界であったが、本発明では搬送管内で不定形耐火組成物と施工水との混合が行われるため、搬送管内での閉塞の心配がなく、200m程度の長距離の搬送や150m程度までの高所の施工を可能にした。
(3)不定形耐火組成物中に急結剤をも含有せしめたため、搬送管途中で急結剤を添加する設備やその制御を行う必要がない。
(4)搬送管内への不定形耐火組成物の付着がないことと、施工後の搬送管内への残存もないため、清掃やメンテナンス作業を大幅に減少させ、さらに搬送管内の残留による不定形耐火材料のロスを著しく低減させた。
(5)得られた吹付け耐火物は、均一で強度の大きい優れた特性を有する。
図1で示した不定形耐火物の吹付け施工装置1を用い、不定形耐火組成物としては、表1に示した組成からなる粉末状の不定形耐火組成物を用いて、次のように気流搬送式吹付け施工を行った。なお、含有量は、分散剤及び遅延剤を除き、不定形耐火組成物100質量部当りの質量部の数値である。
この比較例1では、使用する不定形耐火組成物として、全ての材料を予め混合した以外は、実施例1と同一の構成、操作により不定形耐火組成物の吹付け施工を行った。すなわち、予め全ての材料を混合して不定形耐火組成物を調製後、すぐに吹付け施工を行った場合と、不定形耐火組成物を30℃で120日間保管した後、吹付け施工を行った場合の2つの施工を行った。
実施例1と及び比較例1において、材料を調製後すぐに施工した場合と、材料を高温貯蔵した後に施工を行った場合について、それぞれ吹付けパネルを各5枚作成し、1日以上自然乾燥させた後、カッターにて厚み方向に切断して施工体の切断面観察を行い、さらに、パネルの110℃乾燥後の嵩密度および曲げ強さを測定し、それらの試験結果を表2にまとめて示した。
*2 曲げ強度:JIS R 2553に準拠して測定した。
*3 切断面観察:厚み方向に切断した切断面を目視観察し、骨材の偏在や層状剥離部分(ラミネーション)を調査した。評価は次のとおり行った。
[骨材の偏在]あり:偏在が確認されたもの、なし:偏在が確認されなかったもの
[ラミネーション]あり:剥離部分があったもの、なし:剥離部分がなかったもの
*4 充填性:厚み方向に切断した複数の切断面を目視観察し、微小空隙の有無で判断した。
良好:いずれの面にも空隙なし、若干不良:切断面により半数以下の面に空隙あり、不良:半数以上の面に空隙あり
なお、2012年3月30日に出願された日本特許出願2012-080934号の明細書、特許請求の範囲、図面及び要約書の全内容をここに引用し、本発明の明細書の開示として、取り入れるものである。
Claims (8)
- 耐火性骨材、耐火性粉末、結合剤及び分散剤を含む不定形耐火材料に、気流搬送直前に、粉体急結剤を添加、混合して不定形耐火組成物とする混合工程と、
前記不定形耐火組成物を、粉末の状態のまま気流に乗せて搬送管の一端側から前記搬送管内に送り込み他端側へ搬送する気流搬送工程と、
前記気流搬送工程で搬送中の前記不定形耐火組成物に施工水を添加する施工水添加工程と、
前記施工水が添加された不定形耐火組成物を、吹付けノズルから施工対象物に吹付ける吹付け工程と、
を有することを特徴とする不定形耐火物の気流搬送式吹付け施工法。 - 前記混合工程が、定量搬送される前記不定形耐火材料に前記粉体急結剤を所定量供給して混合することにより行われる請求項1に記載の不定形耐火物の気流搬送式吹付け施工法。
- 前記耐火性粉末が平均粒子直径が10μm以下の耐火性超微粉であり、前記結合剤がアルミナセメントであり、前記分散剤が縮合リン酸塩、カルボン酸塩又はスルホン酸塩であり、かつ前記粉体急結剤がアルカリ金属若しくはアルカリ土類金属のケイ酸塩、アルミン酸塩、炭酸塩又は硫酸塩である請求項1または2に記載の不定形耐火物の気流搬送式吹付け施工法。
- 耐火性超微粉が、アルミナ及び/又はヒュームドシリカである請求項3に記載の不定形耐火物の気流搬送式吹付け施工法。
- 粉体急結剤がアルミン酸ナトリウムである請求項3または4に記載の不定形耐火物の気流搬送式吹付け施工法。
- 前記耐火性粉末、結合剤、分散剤及び粉体急結剤の含有量が、前記耐火性骨材100質量部あたり、それぞれ、30~60質量部、2.5~20質量部、0.03~1.5質量部及び0.07~4.5質量部である請求項1~5のいずれか1項に記載の不定形耐火物の気流搬送式吹付け施工法。
- 前記施工水の添加位置が、前記ノズルの先端から0.3~15m上流である請求項1~6のいずれか1項に記載の不定形耐火物の気流搬送式吹付け施工法。
- 請求項1~7のいずれか1項に記載の不定形耐火物の気流搬送式吹付け施工法により構築された耐火物。
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CN105333736A (zh) * | 2014-08-15 | 2016-02-17 | 中冶宝钢技术服务有限公司 | 一种炉窑耐材维护用自动加料喷补机 |
JP2019137607A (ja) * | 2018-02-09 | 2019-08-22 | Agcセラミックス株式会社 | 不定形耐火組成物 |
CN113087440A (zh) * | 2021-04-20 | 2021-07-09 | 浙江衢州鼎盛建材有限公司 | 一种无碱速凝剂的生产工艺及其生产装置 |
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JP2002220288A (ja) * | 2001-01-16 | 2002-08-09 | Plibrico Japan Co Ltd | 不定形耐火物の吹付け施工方法 |
JP2006298756A (ja) * | 2006-04-20 | 2006-11-02 | Plibrico Japan Co Ltd | 吹付け用不定形耐火組成物 |
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CN105333736A (zh) * | 2014-08-15 | 2016-02-17 | 中冶宝钢技术服务有限公司 | 一种炉窑耐材维护用自动加料喷补机 |
CN105333736B (zh) * | 2014-08-15 | 2017-07-28 | 中冶宝钢技术服务有限公司 | 一种炉窑耐材维护用自动加料喷补机 |
JP2019137607A (ja) * | 2018-02-09 | 2019-08-22 | Agcセラミックス株式会社 | 不定形耐火組成物 |
JP7282539B2 (ja) | 2018-02-09 | 2023-05-29 | Agcセラミックス株式会社 | 不定形耐火組成物 |
CN113087440A (zh) * | 2021-04-20 | 2021-07-09 | 浙江衢州鼎盛建材有限公司 | 一种无碱速凝剂的生产工艺及其生产装置 |
CN113087440B (zh) * | 2021-04-20 | 2022-02-11 | 浙江衢州鼎盛建材有限公司 | 一种无碱速凝剂的生产工艺及其生产装置 |
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