Spray-on fireproof coating composition made from recycled acidic and neutral waste refractories

Abstract

The spray-on refractory coating composition is made by recycling acidic or neutral waste refractories, and contains 10-80% by weight of residual aggregate from acidic or neutral waste refractories, 5-55% by weight of binder, 5-35% by weight of heat absorbing material, 0.3-1.7% by weight of organic fiber, 0.5-3.5% by weight of quick-setting agent, 0.1-0.7% by weight of thickener, 0.1-0.9% by weight of fluidizing agent, and 0.05-0.15% by weight of AE (Air Entraining agent). Most of the acidic and neutral waste firebricks that are used as firebricks for blast furnaces in steel factories and then landfilled in public waters can be recycled and used as the main component of a fire-resistant spray coating material, which can reduce the amount of waste firebricks discarded and contribute to resource conservation and global environmental protection. It can prevent the collapse of structures by preventing concrete explosions in the event of a fire at construction and civil engineering sites, as well as the risk of steel structures collapsing in the event of a fire due to high temperatures. It has good insulation properties at high temperatures and can be used to repair and reinforce damaged areas of existing concrete structures.

Description

[Technical field]

[0001] The present invention relates to a fire-resistant spray coating composition, and more particularly to a fire-resistant spray coating composition made from recycled acidic or neutral waste refractories. [Background technology]

[0002] Currently, with the increase in the development of skyscrapers, large-scale complex buildings, and underground spaces and tunnels, as well as the resulting expansion of certification systems, the market for fire-resistant coating materials and fire-resistant spraying materials is showing a tendency to grow by more than 12% per year.

[0003] When looking at the effect of temperature on concrete during a fire, dehydration begins at around 250°C, calcium hydroxide decomposes at 450-500°C and releases crystalline water, calcium carbonate decomposes at 600-700°C or higher, and complete dehydration of the cement paste occurs at 900°C. When concrete is exposed to high heat, properties such as compressive strength and elastic modulus decrease, but the higher the temperature of the concrete, the greater the degree of decrease, and when the decrease becomes severe, it collapses. In addition, when concrete is exposed to high temperatures, an explosion phenomenon occurs in which the surface layer peels off and scatters. In this case, serious damage to the structure may occur, leading to rapid collapse. In the event of a large-scale fire, it may take a long time to extinguish the fire, which may cause severe damage. As a fireproofing measure against such large-scale fires, the concrete members can be protected by spraying a certain thickness of fireproof mortar on them.

[0004] In general, steelworks use refractories as interior or repair materials of various materials according to the operating characteristics of various furnaces such as blast furnaces, TLCs (Torpedo Laddle Cars), ladles, converters, vacuum degassing equipment (Ruhrstahl-Heraeus), tundishes, heating furnaces, and electric furnaces. Refractories for steelmaking are generated most frequently in the pig iron and steelmaking processes, where metal ash is put in and transported or processed, and most of these refractories are discarded after a certain period of use, with only a small portion (approximately 5 to 6%) being recycled as refractory raw materials.

[0005] In Korea, waste refractory recycling companies collect waste refractories, remove only surface impurities, and sell them as refractory raw materials, etc. However, the refractory raw materials are currently recycled only as refractory raw materials for steel. Therefore, since there are limitations on recycling the refractory raw materials, low-priced products are imported to meet demand, which often results in a deterioration in quality. Summary of the Invention [Problem to be solved by the invention]

[0006] The present invention has been made to solve the above-mentioned problems in the prior art, and an object of the present invention is to provide a spray-on refractory coating material composition made from recycled acidic or neutral waste refractories discarded from steelworks, which can be recycled as a fire-resistant insulating aggregate to increase the recycling rate and thereby save resources.

[0007] Another object of the present invention is to provide a sprayable refractory coating composition made by recycling waste acidic or neutral refractories, which is excellent in fire resistance, compressive strength and water retention and can be used for both architectural and civil engineering purposes by incorporating the waste acidic or neutral refractories into a sprayable hydraulic refractory mortar composition. [Means for solving the problem]

[0008] In order to achieve the above-mentioned object of the present invention, the refractory spray coating material composition recycled from acidic or neutral waste refractories according to one embodiment of the present invention comprises 10 to 80 wt% of acidic or neutral waste refractory residual aggregate, 5 to 55 wt% of binder, 5 to 35 wt% of heat absorbing material, 0.3 to 1.7 wt% of organic fiber, 0.5 to 3.5 wt% of quick-setting agent, 0.1 to 0.7 wt% of thickener, 0.1 to 0.9 wt% of fluidizing agent, and 0.05 to 0.15 wt% of AE (Air Entraining agent).

[0009] In the spray coating composition for fireproof coating material made by recycling acidic or neutral waste refractories according to one embodiment of the present invention, the residual aggregate of the acidic or neutral waste refractories may be at least one of Al-Si-C, plate, inflow material, general castable alumina, and T / D alumina.

[0010] In the refractory spray coating material composition recycled from acidic or neutral waste refractories according to one embodiment of the present invention, the acidic or neutral waste refractory residual aggregate may contain 10-30% by weight of Al-Si-C, 10-30% by weight of Plate, 10-30% by weight of Inflow material, 10-30% by weight of General Castable Alumina, and 10-30% by weight of T / D Alumina.

[0011] In the spray coating composition made from recycled acidic or neutral waste refractories according to one embodiment of the present invention, the acidic or neutral waste refractories remaining aggregate may be crushed to have a particle size of 4 mm or less.

[0012] In the sprayed refractory coating composition made by recycling acidic or neutral waste refractories according to one embodiment of the present invention, the binder may be at least one of Portland cement and alumina cement.

[0013] In one embodiment of the present invention, the composition for spray-on fireproof coating material made by recycling waste acidic or neutral refractories has a melting point of 1200°C or higher, and can prevent damage at 1200°C for 3 hours.

[0014] In the sprayed refractory coating composition made by recycling acidic or neutral waste refractories according to one embodiment of the present invention, the heat absorbing material may include at least one of lime, gypsum, and aluminum hydroxide.

[0015] In the spray-applied fireproof coating material composition made by recycling acidic or neutral waste refractories according to one embodiment of the present invention, the organic fiber may include at least one of polypropylene, acrylic, rayon, vinylon, and polyethylene fibers.

[0016] In the refractory spray coating material composition made by recycling acidic or neutral waste refractories according to one embodiment of the present invention, the quick-setting agent may include at least one of a cement mineral system, an aluminate system, a silicate system, or an alkali-free system.

[0017] In the refractory spray coating material composition made by recycling acidic or neutral waste refractories according to one embodiment of the present invention, the thickener may include at least one of methyl cellulose and polyvinyl acetate. Effect of the Invention

[0018] According to the sprayable refractory coating composition made by recycling waste acidic or neutral refractories according to the present invention, waste acidic or neutral refractory bricks, most of which are used as refractory bricks for blast furnaces in steel plants and then disposed of in landfills on public water bodies, can be recycled and used as a main component of sprayable hydraulic refractory mortar, thereby reducing the amount of waste refractories, thereby contributing to resource conservation and global environmental protection.

[0019] In addition, the spray-on fireproof coating material composition made from recycled acidic or neutral waste refractories according to the present invention can prevent the collapse of structures at construction and civil engineering sites by preventing concrete spalling in the event of a fire, and can also prevent the risk of steel structures collapsing in the event of a fire due to high temperatures.

[0020] Lightweight fireproof materials have large internal voids, which reduces their insulating properties at high temperatures. However, the spray-on fireproof coating composition of the present invention made from recycled acidic or neutral waste refractories has small internal voids, so it has good insulating properties at high temperatures, and when applied to damaged areas of existing concrete structures, it can exert a repair and reinforcement effect by expressing structural strength. [Brief description of the drawings]

[0021] [Figure 1a] 1 is a quality inspection report of the residual aggregate of recycled acidic / neutral waste refractories used in a fireproof coating composition made from recycled acidic / neutral waste refractories according to one embodiment of the present invention. [Figure 1b] 1 is a quality inspection report of the residual aggregate of recycled acidic / neutral waste refractories used in a fireproof coating composition made from recycled acidic / neutral waste refractories according to one embodiment of the present invention. [Figure 1c] 1 is a quality inspection report of the residual aggregate of recycled acidic / neutral waste refractories used in a fireproof coating composition made from recycled acidic / neutral waste refractories according to one embodiment of the present invention. [Figure 1d] 1 is a quality inspection report of the residual aggregate of recycled acidic / neutral waste refractories used in a fireproof coating composition made from recycled acidic / neutral waste refractories according to one embodiment of the present invention. [Diagram 2] 1 is a report of quality inspection of a refractory mortar made of a refractory spray coating material composition made by recycling acidic or neutral waste refractories according to one embodiment of the present invention. [Diagram 3] 1 is a test report showing the test results for each item in Tables 1 and 2 for a refractory spray coating material composition made by recycling acidic or neutral waste refractories according to one embodiment of the present invention. [Figure 4] 1 is a test report showing the test results for each item in Tables 1 and 2 for a refractory spray coating material composition made by recycling acidic or neutral waste refractories according to one embodiment of the present invention. [Diagram 5] 1 is a test report showing the test results for each item in Tables 1 and 2 for a refractory spray coating material composition made by recycling acidic or neutral waste refractories according to one embodiment of the present invention. [Figure 6] 1 is a test report showing the test results for each item in Tables 1 and 2 for a refractory spray coating material composition made by recycling acidic or neutral waste refractories according to one embodiment of the present invention. [Figure 7] 1 is a test report showing the test results for each item in Tables 1 and 2 for a refractory spray coating material composition made by recycling acidic or neutral waste refractories according to one embodiment of the present invention. [Figure 8] 1 is a test report showing the test results for each item in Tables 1 and 2 for a refractory spray coating material composition made by recycling acidic or neutral waste refractories according to one embodiment of the present invention. [Figure 9] 1 is a test report showing the test results for each item in Tables 1 and 2 for a refractory spray coating material composition made by recycling acidic or neutral waste refractories according to one embodiment of the present invention. [Figure 10] 1 is a test report showing the test results for each item in Tables 1 and 2 for a refractory spray coating material composition made by recycling acidic or neutral waste refractories according to one embodiment of the present invention. [Figure 11] 1 is a test report showing the test results for each item in Tables 1 and 2 for a refractory spray coating material composition made by recycling acidic or neutral waste refractories according to one embodiment of the present invention. [Figure 12] 1 is a test report showing the test results for each item in Tables 1 and 2 for a refractory spray coating material composition made by recycling acidic or neutral waste refractories according to one embodiment of the present invention. [Figure 13] 1 is a test report showing the test results for each item in Tables 1 and 2 for a refractory spray coating material composition made by recycling acidic or neutral waste refractories according to one embodiment of the present invention. [Figure 14] 1 is a test report showing the test results for each item in Tables 1 and 2 for a refractory spray coating material composition made by recycling acidic or neutral waste refractories according to one embodiment of the present invention. [Figure 15] 1 is a test report showing the test results for each item in Tables 1 and 2 for a refractory spray coating material composition made by recycling acidic or neutral waste refractories according to one embodiment of the present invention. [Figure 16]1 is a test report showing the test results for each item in Tables 1 and 2 for a fireproof coating composition made from recycled acidic or neutral waste refractories according to one embodiment of the present invention. [Figure 17] 1 is a test report showing the test results for each item in Tables 1 and 2 for a fireproof coating composition made from recycled acidic or neutral waste refractories according to one embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0022] Hereinafter, some embodiments of the present invention will be described in detail with reference to the drawings. When adding reference numerals to components in each drawing, the same components are given the same numerals as much as possible even if they are displayed in different drawings. In addition, when describing the embodiments of the present invention, if a detailed description of related known configurations or functions is judged to hinder understanding of the embodiments of the present invention, the detailed description will be omitted.

[0023] In addition, in describing components of the embodiments of the present invention, terms such as "first," "second," "A," "B," "(a)," "(b)," etc. may be used. These terms are merely used to distinguish the components from other components, and do not limit the essence, order, or sequence of the components. When a component is described as being "coupled," "coupled," or "connected" to another component, the component may be directly coupled or connected to the other component, but another component may also be "coupled," "coupled," or "connected" between each component.

[0024] Hereinafter, a spray-on refractory coating composition made by recycling acidic or neutral waste refractories according to one embodiment of the present invention will be described with reference to the accompanying drawings.

[0025] The sprayed fireproof coating material composition recycled from acidic or neutral waste refractories according to one embodiment of the present invention can contain 10-80% by weight of acidic or neutral waste refractory aggregate, 5-55% by weight of binder, 5-35% by weight of heat absorbing material, 0.3-1.7% by weight of organic fiber, 0.5-3.5% by weight of quick-setting agent, 0.1-0.7% by weight of thickener, 0.1-0.9% by weight of fluidizing agent, and 0.05-0.15% by weight of AE (Air Entraining Agent). Preferably, the sprayed fireproof coating material composition recycled from acidic or neutral waste refractories can contain 45% by weight of acidic or neutral waste refractory aggregate, 31% by weight of binder, 20% by weight of heat absorbing material, 1% by weight of organic fiber, 2% by weight of quick-setting agent, 0.4% by weight of thickener, 0.5% by weight of fluidizing agent, and 0.1% by weight of AE (Air Entraining Agent).

[0026] However, users can change or remove some of the above-mentioned compositions according to the situation. For example, if only fire resistance is required, the ratio of the acidic / neutral waste refractory aggregate can be increased to 80% by weight and the ratio of other compositions can be reduced. In other words, users can change or remove the ratio of the above-mentioned compositions after understanding the situation on-site and flexibly deal with the situation.

[0027] 1a to 1d are quality inspection reports of the recycled aggregate of acidic or neutral waste refractories used in the sprayed fireproof coating material composition made from recycled acidic or neutral waste refractories according to one embodiment of the present invention.

[0028] 1a to 1d, the quality test results of the acidic / neutral recycled waste refractory aggregate show that the aggregate is suitable for use in civil engineering or construction.

[0029] [Table 1]

[0030] Table 1 shows the types and components of recycled raw materials from acidic or neutral waste refractories used in the spray-on refractory coating composition made from recycled acidic or neutral waste refractories according to one embodiment of the present invention.

[0031] Referring to Table 1, the acidic or neutral waste refractory residue aggregate may include at least one of Al-Si-C, plate, inflow material, general castable alumina, and T / D alumina.

[0032] In addition, the acidic / neutral waste refractory aggregate may include 10-30% by weight of Al-Si-C, 10-30% by weight of Plate, 10-30% by weight of inflow material, 10-30% by weight of general castable alumina, and 10-30% by weight of T / D alumina, and preferably includes 20% by weight of Al-Si-C, 20% by weight of Plate, 20% by weight of inflow material, 20% by weight of general castable alumina, and 20% by weight of T / D alumina. That is, as the acidic / neutral waste refractory aggregate, Al-Si-C, Plate, inflow material, general castable alumina, and T / D alumina can be mixed in a ratio of 1:1:1:1:1, respectively. However, the acidic / neutral waste refractory aggregate is not limited to the above ratio range, and can satisfy its performance even if it is mixed in various ratios.

[0033] The acidic or neutral waste refractory aggregate is preferably pulverized to have a particle size of 4 mm or less.

[0034] [Table 2]

[0035] [Table 3]

[0036] Referring to Table 1, the main components of the residual aggregate from the acidic or neutral waste refractory material are alumina (Al2O3) which accounts for a significant portion, with some SiO2 being present, and it can be said that the aggregate has excellent fire resistance. As a result, as shown in Tables 2 and 3, the fire resistance of the refractory mortars produced from the respective residual aggregates from the acidic or neutral waste refractory material were measured using a simple basic mix of hydraulic refractory mortar. Here, the term "remaining aggregate" is an abbreviated expression for the residual aggregate from the acidic or neutral waste refractory material.

[0037] This shows that regardless of whether alumina cement or Portland cement is mixed, all aggregates can produce fireproof mortar with a melting point and fire resistance of 1200°C or higher.

[0038] FIG. 2 is a report of the quality of the refractory mortar made of the sprayed refractory coating material composition recycled from acidic or neutral waste refractories according to one embodiment of the present invention.

[0039] 2, the quality of the sprayed fireproof coating composition was tested by mixing the residual aggregate, heat absorbing material, and other additives. The fireproof performance was sufficient, and the compressive strength and water retention were comparable to those of civil engineering. Here, KSL 5220 means the test for each type (spray plastering, general plastering, masonry, floor) that meets the standard of dry cement mortar.

[0040] Figures 3 to 17 are test reports showing the test results of each item in Tables 1 and 2 for a fireproof coating composition made by recycling acidic or neutral waste refractories according to one embodiment of the present invention. Here, Figure 3 shows the fireproofness of a fireproof mortar made of a composition corresponding to No. 1 in Table 2, Figure 4 shows the fireproofness of a fireproof mortar made of a composition corresponding to No. 2 in Table 2, and Figure 15 shows the fireproofness of a fireproof mortar made of a composition corresponding to No. 13 in Table 3. The other drawings among Figures 3 to 17 also show the fireproofness of a fireproof mortar made of a composition having a number in Table 2 or Table 3 corresponding to a number obtained by subtracting 2 from the number of each drawing.

[0041] 3 to 17, the fireproof mortar according to one embodiment of the present invention can have excellent fire resistance, having a melting point of 1,200° C. or higher, regardless of the aggregate used to form the composition.

[0042] The acidic / neutral waste refractory aggregate has been described above and will not be described here.

[0043] The binder can be at least one of Portland cement or alumina cement, as shown in Tables 2 and 3.

[0044] The cement is used for the purpose of increasing adhesion and strength, and may be one selected from hydraulic cements such as portland cement, white portland cement, alumina cement, high-early-strength portland cement, and ultra-high-early-strength cement, or may be used alone or in combination as a binder. In one embodiment of the present invention, portland cement or alumina cement may be used as the binder.

[0045] When a large amount of cement is used, the adhesion and strength of the fireproof coating material are excellent, but the density and thermal conductivity are increased, reducing the heat resistance effect, and the amount of hydrates formed is increased, so that the amount of steam generated when exposed to high heat increases, increasing the possibility of explosion during a fire. When too little cement is used, the possibility of explosion, density and thermal conductivity are reduced, but the adhesion and strength are reduced, making it difficult to expect sufficient strength as a fireproof lining. Considering these points, it is effective to use 5 to 55% by weight of cement based on the total solid composition. Most preferably, about 31% by weight of cement can be used as a binder.

[0046] The heat absorbing material is a compound contained in the fireproof coating material that can absorb heat while releasing water of crystallization or carbon dioxide gas in the event of a fire, thereby reducing the rapid temperature rise of the internal concrete and coating material, and is added to further reinforce the effects of the present invention. The heat absorbing material can be limestone aggregate, heavy carbon, lime such as slaked lime, gypsum such as gypsum dihydrate and gypsum hemihydrate, aluminum hydroxide, etc., and can be used at 5 to 35% by weight, and most preferably 20% by weight.

[0047] The organic fibers may include at least one of polypropylene, acrylic, rayon, vinylon, or polyethylene fibers.

[0048] The organic fiber effectively increases the binding strength of the composition during application, preventing initial shedding and cracking, and contributes to increasing strength at low temperatures after hardening, and during fire, the fiber melts at a relatively low temperature of around 170°C to generate a large number of voids inside the fireproof coating material, providing a path for moisture movement, thereby reducing the water vapor pressure and thermal stress of the fireproof coating material itself and the surface layer of the concrete, preventing surface peeling and spalling. The organic fiber not only exhibits excellent insulation and fire resistance without damaging the fireproof coating material during fire, but also plays a role in preventing the destruction of concrete structures by quickly releasing gaseous components such as water vapor generated by heating and preventing an increase in vapor pressure inside the concrete and fireproof lining.

[0049] When the organic fibers are used in a large amount, the volume increases, which may cause a decrease in the strength of the material, and when the amount is too small, the path for moisture to move during a fire is small, which may cause the covering material to fall off or explode, and the function as a fire-resistant lining material may be lost. Considering these points, the organic fibers are preferably used in an amount of 0.3 to 1.7% by weight, and most preferably 1% by weight.

[0050] The accelerator is used to accelerate the setting of the binder, and can impart initial strength to the composition and prevent sagging of the composition.

[0051] In one embodiment of the present invention, it is necessary to secure a fast setting time while requiring ultra-high strength, and the accelerator helps this. The accelerator may include at least one of a cement mineral system, an aluminate system, a silicate system, and an alkali-free system. The accelerator is preferably used in an amount of about 0.5 to 3.5% by weight for adhesion performance, and most preferably 2% by weight.

[0052] The thickener is used to maintain the viscosity of the composition in a slurry state for easy application, impart initial binding strength after application, and stabilize the coating layer to prevent sagging before the hydration bonding of the hydratable binder occurs on the application surface.

[0053] In one embodiment of the present invention, one or more organic thickeners such as methyl cellulose and polyvinyl acetate can be used, and the amount of the organic thickener is appropriate from the standpoint of economy and functionality if it is about 0.1 to 0.7% by weight, and 0.5% by weight is most preferable.

[0054] The superplasticizer is one of the admixtures, and is one of the substances added for the purpose of improving workability, low setting, delay, etc. In one embodiment of the present invention, the superplasticizer is preferably used in an amount of 0.1 to 0.9 wt %, and most preferably 0.5 wt %.

[0055] The AE (Air Entraining Agent) is a chemical admixture used to generate fine closed air bubbles inside concrete and improve the workability and freeze-thaw resistance of concrete. In one embodiment of the present invention, the AE agent is preferably used in an amount of 0.05 to 0.15% by weight, and most preferably 0.1% by weight.

[0056] Although the above description refers to an AE agent, the AE agent may contain both pure AE agent and other additives according to the user's intention.

[0057] The refractory mortar made from the spray coating composition made by recycling acidic or neutral waste refractories according to one embodiment of the present invention has a melting point of 1200°C or higher and can prevent damage at 1200°C for three hours.

[0058] The above-described embodiments are merely examples of the present invention for implementing the spray-on refractory coating composition made from recycled acidic or neutral waste refractories. The present invention is not limited to the above-described embodiments, and the technical spirit of the present invention is within the scope of the invention that can be implemented by anyone having ordinary skill in the art to which the present invention pertains, by making various modifications without departing from the gist of the present invention as claimed in the following claims.

Claims

1. Acidic / neutral waste refractory residue aggregate 10-80% by weight, 5 to 55% by weight of binder, Endothermic material 5-35% by weight, 0.3 to 1.7% by weight of organic fibers, Accelerator 0.5 to 3.5% by weight, 0.1 to 0.7% by weight of a thickener, 0.1 to 0.9 wt. % of a superplasticizer; and Contains 0.05 to 0.15% by weight of A.E. (Air Entraining agent) A fireproof coating composition for spray application which is made by recycling acidic and neutral waste refractories.

2. The acidic / neutral waste refractory residual aggregate is at least one of Al-Si-C, plate, inflow material, general castable alumina, and T / D alumina. A fireproof coating composition for spray application, which is made by recycling the acidic and neutral waste refractories according to claim 1.

3. The acidic and neutral waste refractory aggregate is Al-Si-C10-30% by weight Plate 10-30% by weight, Inflow material 10-30% by weight, 10 to 30% by weight of general castable alumina, and Contains 10-30% by weight of T / D alumina A fireproof coating composition for spray application, which is made by recycling the acidic and neutral waste refractories according to claim 1.

4. The acidic and neutral waste refractory aggregate is crushed to have a particle size of 4 mm or less. A fireproof coating composition for spray application, which is made by recycling the acidic and neutral waste refractories according to claim 1.

5. The binder is at least one of Portland cement or alumina cement. A fireproof coating composition for spray application, which is made by recycling the acidic and neutral waste refractories according to claim 1.

6. The melting point of the refractory mortar made from the composition is 1200°C or higher, and it is prevented from breaking at 1200°C for 3 hours. A fireproof coating composition for spray application, which is made by recycling the acidic and neutral waste refractories according to claim 1.

7. The heat absorbing material includes at least one of lime, gypsum, and aluminum hydroxide. A fireproof coating composition for spray application, which is made by recycling the acidic and neutral waste refractories according to claim 1.

8. The organic fibers include at least one of polypropylene, acrylic, rayon, vinylon, and polyethylene fibers. A fireproof coating composition for spray application, which is made by recycling the acidic and neutral waste refractories according to claim 1.

9. The accelerator includes at least one of a cement mineral system, an aluminate system, a silicate system, and an alkali-free system. A fireproof coating composition for spray application, which is made by recycling the acidic and neutral waste refractories according to claim 1.

10. The thickening agent includes at least one of a methylcellulose type and a polyvinyl acetate type. A fireproof coating composition for spray application, which is made by recycling the acidic and neutral waste refractories according to claim 1.

Images