METHOD FOR REPAIRING A GLASS MELTING FURNACE TANK

Abstract

Method for hot repairing a region of a tank of a glassmaking furnace, called the "region to be repaired", by means of a repair product (P), said method comprising the following steps, at a temperature above 300°C: a) defining a receiving space in the region to be repaired, called the "region to be filled", the region to be filled (10) comprising a bottom (12; 12'); b) covering said bottom, the duration of the covering, from the start of the introduction of the repair product into the region to be filled until the moment when said bottom is completely covered by repair product, lasting less than 14 minutes; c) filling the region to be filled with the repair product, the rate of rise (V) of the repair product in the region to be filled being, at all times during said filling step, greater than or equal to 3 mm / min. No abstract figure

Description

Title of the invention: METHOD FOR REPAIRING A GLASS MELTING FURNACE TANK Technical field

[0001] The present invention relates to a method of repairing a tank of a glass melting furnace. Prior art

[0002] The glass industry generally uses, for the construction of its furnaces, refractory products melted and cast, or obtained by sintering, which are very resistant to corrosion by molten glass, and come in the form of blocks or slabs.

[0003] Molten glass is very corrosive and refractory products, particularly those constituting the melting tank, undergo significant wear, which can lead to the creation of leaks of molten glass. These leaks are dangerous and can cause the furnace to shut down.

[0004] In order to increase the lifespan of the furnace, the glassmaker may be required to carry out hot repairs. A hot repair advantageously makes it possible to considerably limit the duration of interruption of the operation of the furnace.

[0005] EP 3 268 328 B1 describes a product for repairing glass melting furnaces as well as a method for hot repairing a region of a glass melting furnace, in particular the floor.

[0006] EP 0 739 861 B1 also describes a method for repairing glass melting furnaces. According to this method, layers of a repair product are superimposed in the regions to be filled.

[0007] Furthermore, products are also used to repair metalworking furnaces. The mechanical constraints in this application are, however, very different from those encountered in the application to a glassmaking furnace. The conditions for corrosion of furnaces by glass or by molten metal are also very different. Finally, certain impurities, tolerated in metalworking furnaces, are unacceptable for glassmaking. In particular, the refractory materials used in glassmaking furnaces must not generate the release of stones by fragmentation, nor produce bubbles. A repair product intended for a metalworking furnace is therefore not, a priori, usable for a glassmaking furnace, in particular in an area in contact with molten glass.

[0008] With current processes, the repaired area remains fragile. The lifespan of the tank is therefore limited.

[0009] There is thus a permanent need for solutions to extend the life of the repaired tank. The present invention aims to satisfy, at least partially, this need. Summary of the invention

[0010] The invention provides a method for hot repairing a region of a tank of a glassmaking furnace, called the "region to be repaired", by means of a repair product, said method comprising the following steps, at a temperature above 300°C, preferably above 400°C, preferably above 500°C, preferably above 600°C, preferably above 700°C, preferably above 800°C, preferably above 900°C, and preferably below 1350°C, preferably below 1300°C: (a) definition of a reception space in the region to be repaired, called the “region to be filled”, the region to be filled comprising a bottom; b) covering said bottom, the duration of covering, from the start of the introduction of the repair product into the region to be filled until the moment when said bottom is completely covered by repair product, being less than 14 minutes; c) filling, preferably by pouring, the region to be filled with the repair product, the rate of rise of the repair product in the region to be filled being, at any time during said filling step, greater than or equal to 3 mm / min.

[0011] In step c), any elementary volume of the region to be filled considered, for example any cubic volume of 1 cm on each side, is thus filled at a rise speed greater than or equal to 3 mm / min.

[0012] As will be seen in more detail in the remainder of the description, the repair method according to the invention makes it possible, surprisingly, to obtain an extension of the service life of the repaired region of the tank. In particular, the inventors have discovered that a rise rate and a coating duration thus controlled give the repaired region a lower open porosity and a mechanical resistance, in particular a compressive strength, higher than with the prior methods. They have also discovered that the microstructure of the region repaired using a method according to the invention is devoid of strata, which could explain the performance obtained.

[0013] For the sake of clarity, a distinction is made between the region of the furnace requiring repair, or "region to be repaired", and the region which, in the filling step, is filled in a controlled manner, i.e. the "region to be filled". Indeed, if in one embodiment the region to be filled merges with the region to be repaired, the region to be repaired may be alternatively partitioned in order to define several regions to be filled with smaller surfaces.

[0014] A method according to the invention may also comprise one or more of the charac- following optional and preferred characteristics:

[0015] • the rising speed varies, during said filling step, between a minimum speed and a maximum speed, the difference between said maximum speed and said minimum rising speed being less than 15 mm / min; • the rate of rise of the repair product is, at any time during said filling step, greater than 7 mm / min, preferably greater than 12 mm / min, and / or less than 80 mm / min; • the duration of the coating step is preferably less than 10 minutes, preferably less than 8 minutes; • the area to be filled has a surface area less than or equal to 25 m2, preferably less than 16 m2, and / or a surface area greater than or equal to 3 m2. • in step b) and / or in step c), preferably in step b) and in step c), the repair product is introduced into the region to be filled with a flow rate greater than 0.02 mVmin and less than 0.60 mVmin; • during filling step c), the repair product is conveyed to the region to be filled by pumping, preferably with a suction pressure less than or equal to 180 bar; • the region to be filled is defined - by the surface of the tank in the area to be repaired and / or - by one or more compartmentalization partitions added to the area to be repaired; • the compartmentalization partitions define, alone or in combination with the surface of the tank in the region to be repaired, a region to be filled included in the region to be repaired; • in step a), the region to be repaired is divided into a plurality of compartments, the region to be filled being one of said compartments; • the method comprises a plurality of cycles of steps b) and c) in order to fill each of said compartments, each compartment constituting a said region to be filled.

[0016] The invention also relates to a method for hot repair of a tank initially containing a bath of molten glass in contact with the region to be repaired, comprising the following steps: 1) emptying, at least partially, said molten glass from the tank, so as to expose said region to be repaired; 2) preferably, rinsing said area to be repaired; 3) reduction of the temperature in the oven; 4) implementation of steps a) to c); 5) preferably, increase and maintain the oven temperature between 900°C and 1400°C to sinter the repair product; 6) introducing a glass composition to be melted into the tank and increasing the temperature of the furnace to an operating temperature leading to the melting of said composition.

[0017] The invention also relates to a glass melting furnace comprising a tank comprising at least one repaired region, preferably repaired according to a method according to the invention, said repaired region being made of a product, preferably sintered, having a non-stratified microstructure.

[0018] Preferably, the product of the repaired region is sintered.

[0019] Preferably, the sintered product of the repaired region has: - an open porosity of less than 40%, preferably less than 35%, preferably less than 30%, and / or - a cold compression strength greater than 30 MPa, preferably greater than 40 MPa, preferably greater than 50 MPa, preferably greater than 55 MPa. Brief description of the figures

[0020] Other characteristics and advantages of the invention will become apparent upon examination of the description which follows and with regard to the appended drawing in which: - [Fig. 1] [Fig. 1] schematically represents, in perspective, a tank presenting two regions to be repaired; - [Fig.2][Fig.2] schematically represents, in perspective, a compartmentalized region to be repaired; - [Fig.3] [Fig.3] schematically represents a region to be filled in the process of being filled. Definitions

[0021] For the sake of clarity, a distinction is made between the “repair product” which is the product which is put in place during the filling step, and the “sintered product” which is the product resulting from the sintering of the repair product after the filling step.

[0022] The term "tank" of a glass melting furnace is conventionally used to refer to the assembly consisting of the floor and the side walls, including the throat, intended to be in contact with the molten glass during the melting of the raw materials. The floor of the tank defines the substantially horizontal bottom of the tank and the vertical walls, which are substantially vertical, surround the bottom.

[0023] The side walls of the tank and / or the compartmentalization partitions installed on the floor can delimit the extent of the bottom of the region to be filled.

[0024] The length and width of the region to be filled are considered to be the major axis and minor axis of the largest ellipse that can be included in the interior opening. (i.e. the opening that leads to the inside of the tank), of the region to be filled. The depth is the largest dimension measured perpendicular to said interior opening.

[0025] The surface area of ​​the bottom of the region to be filled is called the "surface area of ​​the region to be filled". For example, as illustrated in [Fig.l], if the region to be filled 10 is a depression having the general shape of a rectangular parallelepiped, and having a length L, a width 1 and a depth h, the surface area of ​​the region to be filled is equal to the product L*l.

[0026] As illustrated in [Fig.3], the rise speed V is the speed, measured in the vertical direction, at which the repair product P fills the region to be filled 10.

[0027] When the region to be filled has a horizontal bottom 12 or 12', the rise speed is therefore measured perpendicular to the bottom. In [Fig.3], the arrow F illustrates the arrival of the repair product P in the region to be filled.

[0028] “Topping” is a step prior to the filling step.

[0029] The coating begins at the start of the introduction of the repair product into the region to be filled and ends at the moment when the bottom of the region to be filled is for the first time completely covered by repair product. In particular, when the repair product is self-flowing, it is conventionally introduced into the region to be filled by means of a pipe, then flows onto the floor until it reaches the side walls and / or the compartmentalization partitions. It thus gradually covers the entire bottom of the region to be filled. The coating step is finished when the repair product, contained by the side walls and / or the compartmentalization partitions, covers the entire bottom of the region to be filled and is therefore forced to rise in the region to be filled, during the filling step.

[0030] If the bottom has one or more cavities, the filling of these cavities is part of the coating step. Coating is only completed when the entire surface of the repair product introduced into the region to be filled begins to rise.

[0031] A dry particulate mixture is called an “unshaped product”.

[0032] By particle “in a material” or “of a material” is meant a particle consisting of more than 95%, more than 98%, preferably substantially 100% of its mass of said material.

[0033] A hydraulic cement, or "hydraulic binder", is a binder which, upon activation, generates hydraulic setting and hardening.

[0034] By "refractory material" is meant a material having a melting temperature greater than 1500°C. This definition is commonly used by those skilled in the art and cited in "Refractory materials and technical ceramics (elements of ceramurgical and technology)", G. Aliprandi, Septima Paris editions, 1979. This The work also gives on pages 297 to 301 examples of refractory materials, notably oxides, carbides and nitrides.

[0035] The “glass” of the particles (b) mentioned in the remainder of the description is a non-crystalline material having a glass transition temperature of less than 1100°C. By “glass transition temperature” of a glass is meant the temperature at which the material passes from the solid state to the viscous state. The glass transition temperature can be determined by differential thermal analysis (DTA). The glass transition temperature is the temperature at which the glass has a viscosity substantially equal to 1012 Pa.s. A glass is conventionally considered “in the solid state” at a temperature lower than its glass transition temperature. Similarly, as is well known, a glass-ceramic is considered “in the solid state” when it is at a temperature lower than the glass transition temperature of its residual glass phase.

[0036] By "hot binder" is meant a constituent having a melting temperature above 600°C, and capable of binding together, after hardening under the effect of a drop in temperature, particles, in particular particles (a), described below, with which it has been mixed.

[0037] By "glass-ceramic" or "glass-ceramic material" is conventionally meant a microcrystalline compound obtained by controlled crystallization of a "glass-ceramic precursor glass". The controlled crystallization of a glass-ceramic precursor glass is conventionally carried out during a step following, immediately or not, the step of obtaining said glass-ceramic precursor glass.

[0038] A glass-ceramic precursor glass is a solid-state glass which, unlike other glasses, contains "nucleating agents". A nucleating agent is an agent capable of causing the formation of microcrystallizations or "microcrystallites" during controlled crystallization heat treatment, usually called "crystallization heat treatment" or "vitroceramization heat treatment", a microcrystallite being a crystal whose half-sum of the length and width is less than 10 μm. The length and width of a microcrystallite are conventionally evaluated from cross-sectional views of the glass-ceramic.

[0039] The microstructure of a glass-ceramic is thus made up of microcrystallites bathed in a residual glassy phase. The melting temperature of a glass-ceramic material is the equilibrium temperature separating the domain where liquid and solid phases coexist from the domain where only a liquid phase is present. Products manufactured by melting-cooling which, during their manufacture, do not pass through a stage in which they are in the glass state are therefore not glass-ceramic materials. Fused corundum, fused alumina, fused spinels, fused magnesia, fused mullite, fused mullite-zirconia, titanate molten aluminum, possibly doped, and molten nitrides are not, in particular, glass-ceramic materials.

[0040] The term "maximum size" refers to the 99.5 percentile (D99>5) of a powder, this percentile corresponding to the mass percentage of 99.5%, on the cumulative particle size distribution curve of the powder particles, the particle sizes being classified in ascending order. The particle size distributions and the maximum size can be determined using a laser particle size analyzer. The laser particle size analyzer can be a Partica LA-950 from HORIBA. It is clear that particles having a size less than 10 pm (which constitute the "fraction < 10 pm") are counted in the fraction of particles having a size less than 40 pm, that particles having a size less than 2 pm are counted in the fraction of particles having a size less than 40 pm and in the fraction of particles having a size less than 10 pm, etc.

[0041] By "impurities" is meant the unavoidable constituents, introduced unintentionally and necessarily with the raw materials or resulting from reactions with these constituents. Impurities are not necessary constituents, but only tolerated. Preferably the quantity of impurities is less than 2%, less than 1%, less than 0.5%, or even substantially zero.

[0042] By "hot self-pouring" is meant a repair product capable of spreading under its own weight alone, and of filling the region to be filled without leading to segregation, in a temperature range between 300°C and 1350°C. Segregation is considered to occur when the casting face of the product obtained after placement of the repair product and sintering has a surface layer of laitance extending, from said casting face, to a depth of 3 mm or more. This surface layer of laitance can easily be revealed after drying or sintering of the product, the sawing being carried out in a plane perpendicular to the casting face.

[0043] AZS products are products, preferably electrocast, whose main constituents are alumina (A12O3), zirconia (ZrO2) and silica (SiO2). In other words, alumina, zirconia and silica are the constituents with the highest mass contents. These products are well suited for the manufacture of glass furnaces. More particularly, current AZS products are mainly used for the regions in contact with molten glass as well as for the superstructure of glass furnaces. AZS products include in particular products marketed by Saint-Gobain SEFPRO, such as ER-1681, ER-1685 or ER-1711.

[0044] When referring to ZrO2 or zirconia, it is appropriate to understand ZrO2 and traces of HfO2. Indeed, a little HfO2, chemically inseparable from ZrO2 in a fusion process and having similar properties, is always naturally present in zirconia sources at contents generally less than 2%. Hafnium oxide is then not considered an impurity. The HfO2 content in AZS particles is preferably less than 5%, less than 3%, less than 2%.

[0045] “Fibers” are elongated structures, typically with a diameter of 1 μm to 1 mm and a length of up to approximately 60 mm.

[0046] Unless otherwise stated, all percentages are mass percentages based on the oxides. A mass content of an element is expressed in the form of the most stable oxide.

[0047] “Behave” or “understand” or “present” must be interpreted non-limiting manner. Detailed description

[0048] In step a), the region to be filled is defined, which may be the region to be repaired or a part of the region to be repaired. Area to be repaired / filled

[0049] A method according to the invention is intended for the repair of a part of a tank of a furnace containing molten glass. This part of the tank, or “region to be repaired”, therefore defines a volume that the method aims to fill, in a controlled manner, with a repair product.

[0050] [Fig.l] very schematically represents an oven 2 comprising a tank 3 defined by a floor 4 and walls 6.

[0051] The area to be repaired may be included in a wall or in the floor of the tank. Preferably, it is mainly delimited by the floor.

[0052] The region to be repaired 16 may have the shape of a cavity, through or not, for example a region in depression, in particular due to wear, opening towards the interior of the tank via an interior opening.

[0053] When the region to be repaired passes through the tank, the opening through which it opens to the outside of the tank is preferably sealed so that the cavity can retain the repair product before it is sintered. This operation is conventionally called "plating".

[0054] In one embodiment, in particular if the region to be repaired belongs to a wall of the tank, a formwork can be produced to delimit at least one region to be filled and to contain the repair product in the region to be filled after its installation. Any formwork technique resistant to the temperature present in the furnace during the repair can be used, in particular the use of metal plates cooled by water circulation, these plates being dismantled after installation of the repair product. preparation.

[0055] As illustrated in [Fig.l], the region to be repaired 16 may merge with the region to be filled 10.

[0056] In another embodiment and as illustrated in [Fig.2], in particular when the dimensions of the region to be repaired, the nature of the repair product and the equipment for conveying the repair product do not allow the desired rise speed and coating duration to be achieved, the region to be filled 10 is delimited by means of one or more compartmentalization partitions 18, preferably substantially vertical, added to the furnace. These compartmentalization partitions thus make it possible to reduce the surface area of ​​the region to be filled and thus, using the same equipment, to increase the rise speed and reduce the duration of the coating step.

[0057] Compartmentalization is particularly useful when the region to be filled is at least partly defined by the floor.

[0058] Preferably, the region to be filled has a surface area greater than or equal to 3 m2, preferably greater than or equal to 4 m2, preferably greater than or equal to 5 m2, preferably greater than or equal to 6 m2, preferably greater than or equal to 9 m2, and preferably less than or equal to 25 m2, preferably less than 16 m2. Such surfaces are well suited to allow filling according to the invention by implementing current techniques (pumps, canes) used to convey known repair products.

[0059] The depth h of the region to be filled is not limiting. It is preferably greater than 1 cm, preferably greater than 2 cm, preferably greater than 3 cm, preferably greater than 5 cm and / or preferably less than 20 cm, preferably less than 15 cm.

[0060] Generally speaking, the dimensions and shape of the region to be filled can be any, provided that they allow coating and filling under conditions in accordance with the invention.

[0061] The region to be repaired may be divided into several compartments, at least a portion, preferably more than 50% in number of the compartments, preferably each compartment preferably constituting a region to be filled as defined above. Those skilled in the art know easily how to determine the number and dimensions of the compartments for this purpose.

[0062] Preferably, the floor of the glass melting furnace has at least two regions to be filled, one of which has a surface area greater than 3 m2, preferably greater than 4 m2.

[0063] The compartments can be manufactured according to any techniques known to those skilled in the art. In particular, for the sole, the compartments can be manufactured by arranging bricks made of a refractory material, in particular an electrocast material, preferably having a chemical composition close to that of the repair product. The laying of bricks or compartmentalization partitions, preferably carried out outside the furnace, can be carried out, conventionally manually, using cooled tools.

[0064] Preferably, the partitions 18 which delimit the compartments, for example made with said bricks, are not removed after the repair product has been put in place.

[0065] In step b), the bottom of the region to be filled is covered with the repair product. Repair product

[0066] The repair product P is preferably wet, preferably self-flowing when hot.

[0067] Preferably, the repair product is the result of the humidification of an unshaped product. Said humidification can be carried out according to any known technique, for example in a mixer. A person skilled in the art knows how to determine the quantity of water to be used to humidify the unshaped product and obtain the repair product.

[0068] In a first preferred embodiment, in particular when the region to be filled is located at the floor of the furnace tank, the unshaped product comprises A) particles (a) of at least one refractory material other than glass and glass-ceramic, and the main constituent(s) of which are alumina (A12O3) and / or zirconia (ZrO2) and / or silica (SiO2) and / or chromium oxide (Cr2O3), the particles (a) constituting the complement to 100%, B) 2% to 15% of particles (b) of a hot binder chosen from glass-ceramic particles, particles of a glass, in particular of a glass-ceramic precursor glass, and mixtures of these particles, the hot binder not being in the solid state at 1500°C, i.e. the hot binder being chosen so that its glassy phase has a glass transition temperature of less than or equal to 1500°C, C) less than 2% of particles (c) of hydraulic cement, the total quantity of particles (a), (b) and (c) being greater than 93% and less than or equal to 100%, as a percentage by mass relative to the mass of the unshaped product, all of said particles (a) and (b), preferably all of the particles of the unshaped product being distributed, as percentages by mass relative to the mass of the unshaped product, in the following manner: - fraction < 0.5 pm: > 1%, - fraction < 2 pm: > 4%, - fraction < 10 pm: > 13%, - fraction < 40 pm: 25% - 52%.

[0069] In a first main embodiment, all of the particles (b) of the unshaped product comprise, or even consist of, glass particles.

[0070] In a second main embodiment, all of the particles (b) of the unshaped product comprise, or even consist of, glass-ceramic particles and / or glass-ceramic precursor glass particles.

[0071] Preferably, the mass quantity of glass-ceramic particles and / or glass-ceramic precursor glass particles in all the particles (b) of the unshaped product is greater than 10%, preferably greater than 20%, preferably greater than 30%, preferably greater than 50%, preferably greater than 70%, or even greater than 90%, or even greater than 95%, or even substantially equal to 100%, based on the mass of all the particles (b).

[0072] Preferably, all of the particles (b) of the unshaped product consist of glass particles and comprise glass-ceramic precursor glass particles. More preferably, all of the particles (b) of the unshaped product consist of glass-ceramic precursor glass particles.

[0073] Preferably, the unshaped product may comprise one or more of the following characteristics:

[0074] - particles (a) and (b), preferably all the particles of the unshaped product, are distributed as follows, in mass percentages: - fraction < 0.5 pm: < 7%, preferably < 6%, preferably < 5%, and / or even > 2%, and / or - fraction < 2 pm: > 5%, preferably > 6%, preferably > 7% and / or preferably < 18%, preferably < 16%, preferably < 14%, preferably < 12%, and / or - fraction < 10 pm: > 16%, preferably > 19%, preferably > 20% and / or, preferably < 40%, preferably < 35%, preferably < 33%, preferably < 30%, preferably < 28%, and / or - fraction < 40 pm: >27%, preferably > 29%, preferably > 30%, preferably > 33%, preferably > 35%, preferably > 37% and / or preferably < 50%, preferably < 47%, preferably < 45%, preferably < 42%, and / or - fraction between 2 pm and 40 pm: > 16% and / or < 40%; - the maximum size of all particles (a) and (b), preferably the maximum size of all particles of the unshaped product, is less than or equal to 5 mm, preferably less than or equal to 2.5 mm, preferably less than or equal to 2 mm, or even less than or equal to 1.5 mm; - all particles (a) and (b) of a size less than 500 pm, preferably all particles of the unshaped product of a size less than 500 pm, represents more than 50%, preferably more than 55%, preferably more than 60%, preferably more than 65%, or even more than 70% of the mass of said unshaped product; the amount of particles (a) in the unshaped product is greater than 82%, preferably greater than 85%, preferably greater than 91% and / or less than 98%, preferably less than 97%; preferably, the set of particles (a) comprises, in mass percentages based on the mass of the unshaped product: - an AZS particle content greater than 10%, greater than 20% and / or less than 95%; and / or - a reactive alumina content greater than 2%, greater than 3%, greater than 4%, and / or less than 13%, less than 10%, less than 8%; and / or - a calcined alumina content greater than 5%, greater than 10%, and / or less than 38%, less than 35%; and / or - an electrofused alumina content greater than 10%, greater than 20%, greater than 25%, and / or less than 70%, less than 65%; and / or - particles having the following chemical analysis, in percentage by mass based on the oxides: Cr2O3 + A12O3 + ZrO2 + MgO + Fe2O3 + SiO2 + TiO2 > 90%, preferably > 95%, and Cr2O3 + A12O3 > 40%, or even > 50%, or even > 60%, or even > 70%, or even > 80%, or even > 90%, or even > 95%, and Cr2O3 > 9%, or even > 15%, or even > 20%, or even > 29%, or even > 39%, or even > 49%, or even > 59%, or even > 70%, or even > 80%, or even > 90%, and 20% > SiO2 > 0.5%, and other oxides: < 10%, preferably < 5%, the content of said particles being greater than 10%, greater than 20%, greater than 30% and / or less than 95%, and / or - a pigmentary chromium oxide content greater than 5%, greater than 10%, and / or less than 25%, less than 20%; the hot binder is chosen so as not to be in the solid state at a temperature of 1350°C, preferably 1300°C, preferably 1250°C, preferably 1200°C, preferably 1150°C; particles (b) represent more than 3% and less than 13%, preferably less than 12%, preferably less than 10%, preferably less than 9%, preferably less than 8% of the mass of said unshaped product; the particles (b) of the product are preferably distributed as follows, in mass percentages based on the mass of the particles (b): - fraction < 1 mm: > 80%, preferably > 90%, or even >95%, or even substantially 100%, and / or

[0075] -

[0076] - - fraction < 0.5 mm: > 80%, preferably > 90%, and / or - fraction < 0.1 mm: > 25% and / or < 48%, preferably < 45%, and / or - fraction < 0.04 mm: < 30%, preferably <25%, or even < 20%; the particles (b) preferably have a melting temperature greater than 750°C, preferably greater than 800°C, preferably greater than 900°C, and / or less than 1650°C, preferably less than 1600°C, preferably less than 1550°C, or even less than 1500°C; the chemical composition of the particles (b) is chosen so that their melting temperature is lower than the temperature of the region to be filled; in one embodiment, the particles (b) have substantially the same composition as the molten glass in the furnace to be repaired; preferably, the particles (b) are made of a material whose chemical composition comprises more than 90%, preferably more than 94%, preferably more than 97% of oxides; in one embodiment, said material consists substantially entirely of oxides; the particles (b) are made of a material whose chemical composition comprises more than 45%, preferably more than 50%, preferably more than 55% and / or less than 80%, preferably less than 75% of silica, in mass percentage; the particles (b) in a glass-ceramic precursor glass and / or the particles (b) in glass-ceramic have the following chemical composition, in mass percentages based on the oxides and for a total of more than 95%, more than 98%, preferably substantially 100%: - SiO2: 45% - 75%, and - A12O3: 5% - 40%, and - CaO + MgO + Li2O: 3% - 30%, - nucleating agents, expressed in oxide form: 0.1% - 20%; the amount of nucleating agents is preferably greater than 1% and / or less than 10%, preferably less than 5%; preferably, said nucleating agents are chosen from TiO2, ZrO2, P2O5 and their mixtures; the quantity of particles (c) of hydraulic cement is preferably less than 1%, preferably less than 0.5%; preferably, the quantity of particles (c) of hydraulic cement is substantially zero; the total quantity of particles (a), (b) and (c) is preferably greater than 95%, preferably greater than 97%, preferably greater than 98%, preferably greater than 99%, the remainder preferably consisting of other oxides and / or surfactants and / or anti-segregation adjuvants and / or fibers; - the unshaped product comprises a surfactant, preferably between 0.075% and 1% of a surfactant; - the surfactant is a modified polycarboxylate ether; - the unshaped product preferably comprises an anti-segregation adjuvant, preferably in an amount of between 0.05% and 0.5% of the mass of the unshaped product; - in one embodiment, the unshaped product comprises fibers, preferably organic, preferably between 0.01% and 0.06%, preferably between 0.01% and 0.03%; - in one embodiment, the unshaped product does not comprise fibers - the unshaped product is moistened so as to obtain a re-formed product preparation, by adding thereto a quantity of water preferably greater than 8%, preferably greater than 9% and / or less than 13%, less than 12%, by mass relative to the mass of said unshaped product.

[0077] Preferably, at least in this first embodiment, the product Repair Hot Bottom AZS, marketed by the company Saint-Gobain Sefpro, is used.

[0078] In a second preferred embodiment, in particular when the region to be filled is located at the level of a wall of the furnace tank, the unshaped product is chosen from Hot Overcoat AZS and Hot Overcoat Chrom50, marketed by the company Saint-Gobain Sefpro.

[0079] The repair product may be brought to the region to be filled using any technique known to those skilled in the art. Preferably, the repair product is pumped by means of a pump producing a suction pressure preferably less than or equal to 180 bar and preferably conveyed to the region to be filled by means of a water-cooled rod. Passages, for example made by drilling, may be provided to allow the cooled rod to be positioned for this purpose.

[0080] In one embodiment, the repair product is ready for use, i.e. already moistened. Advantageously, the rate of rise of the repair product can be increased and / or the number or capacity of the pumps reduced.

[0081] The repair product is preferably poured into the area to be filled. Duration of coating

[0082] The inventors have discovered that the climb speed greater than or equal to 3 mm / min should be achieved quickly after the repair product has started to be introduced into the area to be filled.

[0083] When the region to be filled is in a wall of the tank, the dimensions of the bottom are reduced so that the product begins to rise shortly after the start of its introduction into the region to be filled. The coating of the bottom of the region to be filled therefore typically lasts less than 14 minutes. The condition of a coating duration which lasts less than 14 minutes is therefore not limiting in practice for a region to be filled in a tank wall.

[0084] On the other hand, when the bottom of the region to be filled is defined by the sole, its horizontal surface can be extended, so that the coating step during which the repair product gradually covers the bottom can be of long duration.

[0085] However, during the coating step, there are portions of the bottom which are not covered by repair product, and portions of the bottom which are covered by repair product. But in the latter, the rate of rise of the repair product is very low, or even zero, and, at a constant feed rate of repair product, lower than the rate of rise during the filling step. The repair product, not constrained laterally, in fact tends to flow by gravity, rather than rising in the region to be filled, in particular if the repair product is self-flowing. If the coating step lasts more than 14 minutes, the inventors have discovered that it can lead to heterogeneity of the sintered product, which can limit its lifetime.

[0086] Preferably, the coating duration, i.e. the duration of the coating step, is less than 12 minutes, preferably less than 11 minutes, preferably less than 10 minutes, preferably less than 9 minutes, preferably less than 8 minutes, or even less than 7 minutes, or even less than 6 minutes, and / or greater than 15 seconds, preferably greater than 20 seconds.

[0087] Preferably, when the region to be filled belongs to the bottom of the tank, the covering time, expressed in minutes, is less than 0.6 min / m2 *S, preferably less than 0.5 min / m2 *S, preferably less than 0.4 min / m2 *S, preferably less than 0.3 min / m2 *S, S being the surface area of ​​the bottom of the region to be filled, expressed in m2.

[0088] To reduce the coating time, it is sufficient to reduce the surface area of ​​the region to be filled or to increase the flow rate of introduction of the repair product into the region to be filled.

[0089] Preferably in step b), the arrival of the repair product is located less than one meter from the center of the bottom of the region to be filled, preferably substantially at the center of the bottom of the region to be filled.

[0090] In step c), the region to be filled is filled.

[0091] Preferably, step c) immediately follows step b), i.e. there is no interruption of the supply of repair product between these steps. Preferably, the supply flow rate is identical and constant during these two steps.

[0092] Preferably in step c), the arrival of the repair product is located less than one meter from the center of the bottom of the region to be filled, preferably substantially at the center of the bottom of the region to be filled.

[0093] During step c), the entire surface of the repair product present in the region to be filled rises. Climb speed

[0094] The inventors found that after rapid topping, a rising speed on greater than or equal to 3 mm / min during the entire filling step significantly improves the properties of the repaired region. Without being bound by this theory, the inventors explain this result by a remarkable homogeneity of the sintered product, that is to say the product resulting from the sintering of the repair product.

[0095] In one embodiment, particularly if the region to be filled belongs to the bottom of the tank, the difference between the maximum rise rate and the minimum rise rate during the filling step is less than 15 mm / min, preferably less than 10 mm / min, preferably less than 8 mm / min, preferably less than 5 mm / min, preferably less than 3 mm / min, preferably substantially zero. A small difference, preferably a substantially constant rise rate, further improves the homogeneity of the sintered product.

[0096] Preferably, said rising speed is, throughout the filling step c), greater than 4 mm / min, preferably greater than 5 mm / min, preferably greater than 6 mm / min, preferably greater than 7 mm / min, preferably greater than 8 mm / min, preferably greater than 9 mm / min, preferably greater than 10 mm / min, and preferably less than 80 mm / min, preferably less than 70 mm / min, preferably less than 60 mm / min, preferably less than 50 mm / min, preferably less than 40 mm / min, preferably less than 30 mm / min.

[0097] In one embodiment, in particular if the region to be filled belongs to the bottom of the tank, the rise speed is preferably always less than 80 mm / min, preferably less than 70 mm / min, preferably less than 60 mm / min, preferably less than 50 mm / min, preferably less than 45 mm / min, preferably less than 40 mm / min, preferably less than 35 mm / min, preferably less than 30 mm / min. Advantageously, these conditions offer the best compromise between the properties of the repair product after sintering and compliance with the constraints linked to the repair site, in particular the space constraints which limit the volume of the pumps used to bring the repair product to the region to be filled, and / or the number of these pumps, as well as the surface area of ​​the regions to be filled.

[0098] Preferably, in step b) and / or in step c), preferably in step b) and in step c), the repair product is introduced into the region to be filled with a flow rate greater than 0.02 mVmin, preferably greater than 0.03 mVmin, preferably greater than 0.05 m3 / min, preferably greater than 0.10 mVmin and / or less than 0.60 mVmin, preferably less than 0.50 mVmin, preferably less than 0.40 mVmin, preferably less than 0.30 mVmin. Hot repair

[0099] A method according to the invention is used for the hot repair of a tank initially containing a bath of molten glass in contact with the region to be repaired. In one embodiment, the method comprises, prior to steps a) to c), the following preliminary steps: 1) emptying, at least partially, said molten glass from the tank, so as to expose said region to be repaired; 2) preferably, rinsing said area to be repaired; 3) reduction of the temperature in the oven.

[0100] The method then comprises the following final steps: 4) implementation of steps a) to c); 5) preferably, increasing and maintaining the oven temperature between 900°C and 1400°C in order to sinter the repair product; 6) introducing a glass composition to be melted into the tank and increasing the temperature of the furnace to an operating temperature leading to the melting of said composition.

[0101] The preliminary steps make it possible to provide access to the region to be repaired, that is to say to expose this region.

[0102] In step 1), the glass is therefore emptied, that is to say the furnace tank is emptied, at least partially, preferably substantially completely, of the molten glass it contains, until the region to be repaired is exposed. The emptying can be carried out using any technique known to those skilled in the art.

[0103] For example, it is possible to cool the molten glass using water lances and to remove the cooled glass from the furnace and / or to remove the molten glass from the furnace, through holes drilled in the hearth or through holes created by the dismantling of one or more electrodes.

[0104] In step 2), optional but preferred, the region to be repaired is rinsed, i.e. freed from glass residue. Preferably, a product suitable for increasing the fluidity of the glass is sprayed, at least on the region to be repaired. The glass thus fluidized is more easily removed from the furnace, in particular in the case of removal of molten glass. Preferably, the fluidizing product is chosen from sodium sulfate, sodium carbonate, soda and mixtures thereof.

[0105] In step 3), the temperature in the oven is reduced.

[0106] Preferably, the temperature in the furnace is reduced to a temperature above 300°C, preferably above 400°C, preferably above 500°C, preferably above 600°C, preferably above 700°C, preferably above 800°C, preferably above 900°C, and preferably below 1350°C, preferably below 1300°C.

[0107] In one embodiment, the repair product used in steps b) and c) contains a hot binder, and in step 3), the temperature in the furnace is reduced to a temperature at which the hot binder is not in the solid state. In particular, when the hot binder is a glass-ceramic and / or a glass, in particular a glass-ceramic precursor glass, the temperature in the furnace is reduced to a temperature which remains higher than the glass transition temperature of the glass phase of the hot binder. The glass transition temperature of the glass phase of the hot binder depends on the nature of the hot binder. The hot binder is preferably chosen so that the glass transition temperature of its glass phase is between 600°C and 1350°C, preferably between 900°C and 1350°C, preferably between 1000°C and 1300°C, preferably between 1150°C and 1250°C.

[0108] In step 4), the repair product is put in place following steps a) to c).

[0109] In step 5), optional, the oven is maintained at a temperature between 900°C and 1400°C, preferably between 1250°C and 1400°C, preferably between 1300°C and 1400°C, in order to allow sintering of the repair product, preferably for a time greater than 8 hours, preferably greater than 10 hours and preferably less than 15 hours.

[0110] Preferably, when the repair product contains particles (b) of glass-ceramic precursor glass, the furnace is maintained at a temperature promoting the nucleation and growth of microcrystallites. A person skilled in the art knows how to determine the temperature range allowing this nucleation and growth.

[0111] In step 6), normal operation of the furnace is resumed: A glass composition to be melted is introduced into the furnace and the temperature thereof is increased to its operating temperature. Examples

[0112] The following non-limiting examples are given to illustrate the invention.

[0113] Two examples were carried out with the same repair product, the rate of rise of the repair product being different.

[0114] To manufacture the repair product, the unshaped product Repair Hot Bottom AZS, marketed by the company Saint-Gobain Sefpro, was mixed, in a mixer with a rotating blade and fixed tank, with 11% water, as a percentage based on the unshaped product, for 5 minutes.

[0115] This unshaped product has the following mass composition, based on the mass of the oxides of the unshaped product: - A12O3: 51.8% - SiO2: 16.8% - ZrO2: 28.7% - Other oxides: 2.7%, consisting of CaO, Na2O, K2O and MgO provided by the glass, as well as impurities.

[0116] For each example, 50 kg of repair product are prepared. This repair product is self-flowing when hot.

[0117] For each example, a flat-bottomed compartment having a length equal to 300 mm and a width equal to 250 mm, i.e. a total surface area equal to 0.075 m2, and a depth equal to 150 mm was produced in an electric furnace, using ER 1681 refractory bricks.

[0118] The furnace was started up so as to reach a temperature of 1300°C, the temperature rise rate being 100°C / h.

[0119] The casting of the repair product into the compartment maintained at 1300°C was carried out using a water-cooled metal rod introduced through an opening made in one of the side walls of the electric furnace.

[0120] For example 1, outside the invention, the repair product was introduced in the form of successive thin layers superimposed, until the compartment was filled. Each layer was made by going back and forth with the cane to spread the repair product in the form of adjacent beads.

[0121] For Example 2, according to the invention, the cane was held stationary and the repair product was poured continuously, the level of the repair product continuously rising above any point on the bottom of the compartment after the topping step. The rate of rise was substantially constant.

[0122] After filling the compartment, the temperature was maintained at 1300°C for 10 hours. The temperature was then reduced gradually, at a rate equal to 100°C / h. The sintered product in the compartment was recovered, observed and then cut.

[0123] The inventors consider that this test reproduces well the conditions encountered during the repair of an oven sole.

[0124] Open porosity was measured by hydrostatic weighing.

[0125] The cold compression strength was measured using an LR150K press marketed by AMETEK-LLOYD, on cylinders with a diameter equal to 30 mm and a height equal to 30 mm taken from the sintered product.

[0126] The following Table 1 provides the filling speeds and results obtained.

[0127] [Tableauxl] Example 1 Example 2 Duration of the coating step (min) 5 0.25 Rising rate (mm / min) 2 40 Open porosity (%) 42 29 Cold compressive strength (MPa) 28 56

[0128] Observation of the sintered product produced according to example 1 shows that it has layers stacked on top of each other and numerous macropores.

[0129] Observation of the sintered product produced according to example 2 shows that, on the contrary, it has a homogeneous texture, an open porosity equal to 29%, 44.8% lower than that of the sintered product produced according to example 1 (equal to 42%), and a compressive strength equal to 56 MPa, 2 times higher than that of the sintered product produced according to example 1 (equal to 28 MPa).

[0130] These remarkable characteristics make it possible to increase the lifespan of the repaired region, and therefore the lifespan of the furnace tank.

[0131] These examples thus demonstrate the very advantageous effect of controlling the coating duration and the rate of rise to ensure continuous progression of the repair product in the region to be filled.

[0132] As is now clearly apparent, the invention thus provides a method for repairing a tank of a glass melting furnace, and in particular a region of the bottom of this tank, this method making it possible to increase the service life of the tank of the furnace.

[0133] A method according to the invention is particularly advantageous for repairing a large area to be repaired, and in particular the floor of the furnace.

[0134] Of course, the present invention is not limited to the embodiments described, provided as illustrative and non-limiting examples.

Claims

Claims

1. Method for hot repairing a region of a tank of a glassmaking furnace, called the "region to be repaired", by means of a repair product (P), said method comprising the following steps, at a temperature above 300°C: a) defining a receiving space in the region to be repaired, called the "region to be filled", the region to be filled (10) comprising a bottom (12; 12'); b) covering said bottom, the duration of the covering, from the start of the introduction of the repair product into the region to be filled until the moment when said bottom is completely covered by repair product, lasting less than 14 minutes; c) filling the region to be filled with the repair product, the rate of rise (V) of the repair product in the region to be filled being, at all times during said filling step, greater than or equal to 3 mm / min.

2. Method according to the preceding claim, in which the rise speed (V) varies, during said filling step, between a minimum speed and a maximum speed, the difference between said maximum speed and said minimum rise speed being less than 15 mm / min.

3. Method according to any one of the preceding claims, in which the rate of rise (V) of the repair product (P) is, at any time during said filling step c), greater than 7 mm / min and / or in which the duration of coating step b) is less than 10 minutes.

4. Method according to the immediately preceding claim, in which the rate of rise (V) of the repair product (P) is, at any time during said filling step, greater than 12 mm / min and / or in which the duration of the coating step b) is less than 8 minutes.

5. Method according to any one of the preceding claims, in which the region to be filled (10) has a surface area less than or equal to 25 m2.

6. A method according to any preceding claim, wherein the region to be filled has an area greater than or equal to 3 m 2 and less than 16 m 2.

7. A method according to any preceding claim, in which in step b) and in step c), the repair product (P) is introduced into the region to be filled with a flow rate greater than 0.02 mVmin and less than 0.60 mVmin.

8. A method according to any preceding claim, wherein the rate of rise of the repair product is, at any time during said filling step, less than 80 mm / min.

9. A method according to any preceding claim, wherein, during the filling step, the repair product is pumped to the region to be filled.

10. Method according to the immediately preceding claim, in which the repair product is conveyed to the region to be filled with a suction pressure less than or equal to 180 bar.

11. Method according to any one of the preceding claims, in which the region to be filled (10) is defined - by the surface of the tank in the region to be repaired and / or - by one or more compartmentalization partitions (18) added in the region to be repaired.

12. A method according to any preceding claim, comprising a step a) in which the region to be repaired is divided into a plurality of compartments, then a plurality of cycles of steps b) and c) in order to fill each of said compartments.

13. A method according to any preceding claim, wherein the region to be filled is at least partly defined by the bottom of the tank.

14. A method according to any one of the preceding claims, said tank containing molten glass, said method comprising the following steps: 1) emptying, at least partially, the molten glass from the tank, so as to expose said region to be repaired; 2) preferably, rinsing said region to be repaired; 3) reducing the temperature in the furnace; 4) carrying out said steps a) to c); 5) preferably, increasing and maintaining the temperature of the furnace between 900°C and 1400°C in order to sinter the repair product; 6) introducing a glass composition to be melted into the tank and increasing the temperature of the furnace to an operating temperature leading to the melting of said composition.

15. A method according to any preceding claim, in wherein the repair product is the result of moistening an unshaped product by adding thereto a quantity of water greater than 8%, by mass relative to the mass of said unshaped product.

16. Glass melting furnace comprising a tank comprising at least one region repaired according to a method according to any one of the preceding claims and in a product, preferably sintered, having a non-stratified microstructure.

17. Glass melting furnace according to the immediately preceding claim, wherein said sintered product has: - an open porosity of less than 40%, preferably less than 35%, preferably less than 30%, and / or - a cold compression strength of greater than 30 MPa.

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