Self-Curing Aluminate Paste for Alkali-Resistant Thermal Insulation
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Solution Overview
Problem
Refractory linings and steel anchors in high-temperature furnaces are prone to damage from alkali compounds, leading to reduced longevity and safety, and increased energy consumption due to the formation of alkali condensates and corrosive vapors, with existing coatings failing to provide adequate protection against these aggressive substances.
Innovation Solution
A paste composed of granular and/or powdered alkali metal and alkaline earth metal aluminates, a CaO-free binder, a liquefier, stabilizing agents, and a setting retarder is used to form a high-temperature-resistant thermal insulation material that can be applied as a protective layer, reducing thermal conductivity and enhancing corrosion resistance, allowing for extended service life and reduced energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional fire-retardant coatings based on alkali metal silicates are used, then temperature resistance is improved, but the coatings crack when exposed to elevated temperatures and provide inadequate protection against alkali compounds
Solution Approach 1:
The patent uses a composite material system consisting of calcium aluminate cement as the binder and alumina (Al2O3) as the aggregate. This composite provides both high temperature resistance (stable up to 1300°C) and chemical inertness against alkali compounds, eliminating the cracking and corrosion problems of conventional silicate-based coatings. The specific composition (calcium aluminate cement with 40-60% Al2O3 content combined with alumina aggregate) creates a refractory concrete that maintains structural integrity at elevated temperatures while resisting alkali attack.
2Temperature
If refractory linings are used to protect against high temperatures, then temperature resistance is improved, but alkali compounds penetrate through and damage the steel anchors and supporting structures
Solution Approach 1:
The patent creates an inert chemical environment by using calcium aluminate cement and alumina, both of which are chemically inert to alkali compounds. The refractory concrete coating forms a protective barrier that prevents alkali vapors and condensates from reaching and corroding the steel anchors and supporting structures. The material's chemical stability ensures that no harmful reactions occur between the lining and alkali compounds in the flue gas.
3Use of energy by stationary object
If existing protective coatings are applied to steel anchors, then some temperature protection is achieved, but the coatings fail to prevent destructive penetration of alkali vapors in temperatures up to 1300°C
Solution Approach 1:
The patent changes the chemical composition parameters of the protective coating by using calcium aluminate cement with specific Al2O3 content (40-60%) combined with alumina aggregate. This parameter change transforms the coating from a conventional organic or silicate-based paint to a refractory concrete with fundamentally different chemical properties. The new composition provides both thermal insulation and chemical resistance to alkali vapors at temperatures up to 1300°C, where conventional coatings fail.
4Ease of manufacture
If conventional cement compositions are used for refractory linings, then ease of application is improved, but they lack resistance to alkali and chlorine compounds corrosion
Solution Approach 1:
The patent modifies the chemical composition parameters by replacing conventional Portland cement with calcium aluminate cement and adjusting the aggregate composition to include alumina. This parameter change maintains the workability and ease of application of conventional cement-based coatings while fundamentally improving chemical resistance. The calcium aluminate cement system allows for simple mixing and application similar to conventional coatings but provides superior resistance to alkali and chlorine compound corrosion.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The paste significantly increases the resistance of refractory linings and steel anchors to alkali and chlorine compounds, doubles the service life of high-temperature plants, reduces thermal load and corrosion, and lowers energy consumption while maintaining product quality, with the thermal insulation material being resistant up to 1300°C and having low thermal conductivity.
Implementation Method 1
a paste that hardens itself to form a thermal insulation material
Implementation Method 2
form a thermal insulation material formed from it... low thermal conductivity
Implementation Method 3
a mixture of granular and/or powdered alkali aluminate and an alkaline earth aluminate... Water is mixed in to make the paste
Data Source
AI summary
The invention relates to a paste that self-cures to form a heat-insulating material, wherein a mixture of alkali metal aluminate and/or alkaline earth metal aluminate, suspending agents, and stabilizers is adjusted to a viscosity capable of pumping, spraying, filling, and/or coating by adding water.