Fused Cast AZS Brick Exudation Control via Al2O3-Na2O Ratio
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Solution Overview
Problem
Fused cast AZS bricks used in glass tanks exhibit a high tendency to exudate, contaminating molten glass due to their low viscosity vitreous phases, despite previous attempts to reduce this issue by modifying the SiO2 and Na2O ratios.
Innovation Solution
A fused cast refractory material with a vitreous phase comprising Al2O3 and Na2O, where the molar ratio between Al2O3 and Na2O is within the range of 0.8 to 1.6, significantly reducing the exudation tendency by forming highly viscous molten phases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If the fraction of vitreous phases is reduced in fused cast AZS bricks, then the exudation tendency is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent applies parameter changes by precisely controlling the chemical composition parameters of the vitreous phase, specifically the molar ratio of Al2O3 to Na2O within 0.8 to 1.6. This parameter optimization reduces the exudation tendency while maintaining manufacturing feasibility through standard fusion casting processes.
Solution Approach 2:
The patent uses composite materials by creating a vitreous phase composed of multiple components (Al2O3, Na2O, SiO2, ZrO2) in specific proportions. This composite approach allows the material to exhibit low exudation properties while remaining manufacturable using conventional AZS brick production methods.
2Object-generated harmful factors
If the ratio of SiO2 and Na2O in the vitreous phase is adjusted to reduce molten phase formation, then the exudation is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The patent establishes a specific parameter range for the molar ratio of Al2O3 to Na2O (0.8 to 1.6) which balances exudation reduction with manufacturing precision requirements. This parameter definition provides clear target values for production while avoiding excessive precision demands.
3Object-generated harmful factors
If the molar ratio of Al2O3 to Na2O in the vitreous phase is increased beyond 1.6, then the exudation tendency decreases, but the material composition flexibility is reduced
Solution Approach 1:
The patent defines an optimal parameter range (molar ratio of Al2O3 to Na2O from 0.8 to 1.6) that achieves low exudation tendency while maintaining composition flexibility. This range allows for adjustments in other compositional parameters to optimize specific application requirements without compromising the fundamental exudation resistance.
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 material exhibits a substantially reduced tendency to exudate, as demonstrated by a factor of 10 to 20 lower exudation compared to bricks with slightly higher molar ratios, maintaining glass quality and reducing contamination.
Implementation Method 1
the vitreous phases form melting phases with low melting point that may be sweated out of the brick and come into contact with the molten glass due to their low viscosity
Implementation Method 2
This sweating out of the molten phase fractions of the vitreous phase, also called to as exudation, may contaminate the molten glass
Data Source
AI summary
The invention relates to a fused cast refractory material based on aluminium oxide, zirconium dioxide and silicon dioxide, and a use of such a material.