Boron-Free Sintering Agent for Refractory Compositions
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Solution Overview
Problem
Existing dry particulate refractory compositions using boron-containing sintering agents face regulatory challenges due to classification as Carcinogenic, Mutagenic, and Reprotoxic, and alternative agents fail to maintain effective cohesion and resistance to metal infiltration at high temperatures.
Innovation Solution
A sintering agent comprising at least 70 wt.% refractory aggregates, 1-99 wt.% phosphate compounds with a loss on ignition of less than 20%, and 1-99 wt.% mineral feldspar, which excludes boron compounds, providing effective cohesion and resistance to metal infiltration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If boron-containing compounds are used as sintering agents, then effective cohesion and resistance to metal infiltration are achieved, but regulatory compliance deteriorates due to CMR classification
Solution Approach 1:
The patent removes harmful boron-containing compounds from the sintering agent composition while maintaining the essential sintering function through alternative phosphate-based compounds, thereby eliminating CMR classification issues while preserving technical performance
Solution Approach 2:
The patent changes the chemical composition parameters of the sintering agent by replacing boron compounds with phosphate compounds having specific loss on ignition characteristics (less than 20% at 900°C), achieving both regulatory compliance and effective sintering performance
2Object-affected harmful factors
If alternative sintering agents are used to avoid boron compounds, then regulatory compliance improves, but cohesion and resistance to metal infiltration deteriorate
Solution Approach 1:
The patent optimizes the loss on ignition parameter of phosphate compounds to be less than 20% at 900°C, which ensures adequate sintering performance and resistance to metal infiltration while maintaining regulatory compliance
Solution Approach 2:
The patent creates a composite sintering agent system combining phosphate compounds with specific refractory aggregates, achieving synergistic effects that provide both regulatory compliance and superior cohesion and resistance to metal infiltration
3Object-affected harmful factors
If traditional sintering agents are replaced, then health and safety performance improves, but sintering effectiveness may deteriorate
Solution Approach 1:
The patent extracts and eliminates harmful boron-containing compounds from the sintering process while replacing them with safe phosphate-based alternatives that maintain full sintering effectiveness
Solution Approach 2:
The patent controls the loss on ignition parameter of phosphate compounds to ensure they provide adequate sintering effectiveness while being free from harmful boron compounds, thus improving health and safety without sacrificing performance
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 solution ensures effective resistance to metal infiltration and wear, maintains refractory material performance, and complies with regulatory standards by avoiding boron-containing compounds, offering a wide sintering temperature range and improved durability.
Implementation Method 1
During the thermal consolidation processing, the sintering agent generally changes from the solid state to a viscous liquid state, allowing the grains to coalesce
Implementation Method 2
The thermal consolidation processing temperature, also referred to as sintering temperature, is generally between the sintering agent melting temperature and that of the refractory particles
Data Source
AI summary
The present invention relates to a sintering agent for dry particulate refractory compositions and dry particulate refractory compositions. The use of dry particulate refractory compositions also form part of the present invention.