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Treated refractory material and methods of making

a refractory material and treatment technology, applied in the field of slagging gasifiers, can solve problems such as refractory degradation

Inactive Publication Date: 2009-07-30
GENERAL ELECTRIC CO
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

"The patent describes a way to treat refractory materials to make them more resistant to damage from slag and extend their lifespan. This is done by adding a protective material to the refractory material, which can be in the form of aluminum oxide, chromium oxide, silica, rare earth oxides, or other materials. This treatment can be done by blending the refractory material with a protective material or by adding a precursor of the protective material. The protective material can be in elemental or compound form and can include silicon, rare earth elements, zirconium, titanium, yttrium, magnesium, iron, or blends of these elements. Overall, this treatment is cost-effective and can improve the performance of refractory materials in high-temperature applications."

Problems solved by technology

This infiltration causes refractory degradation through a combination of grain dissolution, grain undercutting and macro-cracking.

Method used

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  • Treated refractory material and methods of making
  • Treated refractory material and methods of making
  • Treated refractory material and methods of making

Examples

Experimental program
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Effect test

example 1

[0049]A sintered high chromia (90 wt %) brick was infiltrated with chromium (III) nitrate solution multiple times followed by subsequent heat treatments in air at 600° C. for 2 hours to decompose the nitrate salt into chromium oxide. The weight of the protective material constituted approximately 10 percent by weight of the refractory brick after all infiltrations. The infiltrated brick was then annealed in nitrogen at 1600° C. for 20 hours to pre-react the chromium oxide before the slag infiltration. The porosity of the untreated refractory before the slag infiltration was about 18-20 vol. %. After infiltration and heat treatment, the porosity was about 12-14 vol. %.

[0050]A slag infiltration test via isothermal annealing of cups filled with slag was performed on the brick infiltrated with chromium oxide and on an untreated brick. The slag composition contained 59.0% silica, 10.7% aluminum oxide, 8.3% calcium oxide, 21.6% iron oxide and 0.3% potassium oxide. Test parameters were 149...

example 2

[0052]Example 1 was reproduced with the exception of using chromium (III) acetate (Cr3(OH)3(CH3COO)2 as the precursor to the chromium oxide protective material. A slag infiltration test via isothermal annealing of cups filled with slag was performed on the brick infiltrated with chromium oxide and on an untreated brick. Test parameters were 1500° C. for 20 hours at an oxygen partial pressure of 10̂-10 atm provided via a mixture of wet and dry N2 / 3% H2 gas.

[0053]Subsequent analysis of slag penetration by XRF mapping of Si distribution at the brick cross-section revealed that slag penetration in the treated brick is much less than the slag penetration in the untreated brick. FIG. 3A shows an XRF mapping of Si of the slag penetration of the untreated brick and the brick treated with chromium oxide.

example 3

[0054]Example 1 was reproduced with the exception of using aluminum nitrate as the precursor for the aluminum oxide protective material. A slag infiltration test via isothermal annealing of cups filled with slag was performed on the brick infiltrated with aluminum oxide and on an untreated brick. Test parameters were 1500° C. for 20 hours at an oxygen partial pressure of 10̂-10 atm provided via a mixture of wet and dry N2 / 3% H2 gas.

[0055]Subsequent analysis of slag penetration by XRF mapping of Si distribution at the brick cross-section revealed that slag penetration in the treated brick is much less than the slag penetration in the untreated baseline brick. FIG. 3B shows an XRF mapping of Si of the slag penetration of the untreated brick and the brick treated with aluminum oxide.

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Abstract

A treated refractory material includes a refractory material having a plurality of pores, wherein the refractory material comprises aluminum oxide, silicon oxide, magnesium oxide, chromium oxide, zirconium oxide, titanium oxide, calcium oxide, fireclay, silicon carbide, tungsten, mullite, dolomite, magnesite, magnesium aluminum oxide, chromite, magnetite, or a combination comprising at least one of the foregoing; and a protective material disposed within the plurality of pores of the refractory material, wherein the protective material is selected from the group consisting of aluminum oxide, chromium oxide, silica, rare earth oxides, rare earth zirconates, titanium oxide, mullite, zirconium oxide, zirconium silicate, yttrium oxide, magnesium oxide, iron oxide, and blends thereof.

Description

CROSS REFERENCE TO RELATED APPLICATION[0001]This application is a continuation-in-part of and claims benefit to the legally related application, U.S. Non-provisional patent application Ser. No. 11 / 683,260 filed Mar. 7, 2007, which is fully incorporated herein by reference.BACKGROUND OF THE INVENTION[0002]In a slagging gasifier, solid feedstocks such as coal or coke are partially oxidized at about 1300 to 1600 degrees Celsius to produce a mixture of carbon monoxide, carbon dioxide, hydrogen, and water (often referred to as a ‘syngas’). The coal can typically contain up to about 5 to 25 percent by weight of inorganic minerals that combine to form a low viscosity molten slag, which contains silicon oxide, aluminum oxide, calcium oxide, and iron oxide.[0003]The walls of the gasifier are lined with refractory material, which is currently prepared from chromium oxide (Cr2O3) grains or a blend of Cr2O3 and aluminum oxide grains, formed into bricks and sintered. The refractory material has ...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): C21B7/06
CPCB82Y30/00C04B35/12C04B35/657C04B41/009C04B41/4535C04B41/5007C04B41/5031C04B41/85C04B41/87C04B2235/3217C04B2235/3224C04B2235/3229C04B2235/3241C04B2235/3244C04B2235/3418C04B2235/443C04B2235/449C04B2235/5454C04B2235/616C04B2235/77C04B2235/9669C04B41/455C04B41/5033C04B41/5045C04B41/5042C04B35/047C04B35/00C04B41/4539C04B41/4549C04B38/00
Inventor TABER, WADE ALBERTCHEN, WEIMESCHTER, PETER JOELSHUBA, ROMAN
Owner GENERAL ELECTRIC CO
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