Fused Cast Refractory with Spinel Crystals for Alkaline Corrosion
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Solution Overview
Problem
Current fused cast refractory products, particularly those with high alumina content, lack sufficient resistance to corrosion by alkaline condensates, such as NaOH, and thermal variations, especially under reducing conditions common in modern glass furnace operations.
Innovation Solution
A fused cast refractory product with a chemical composition of 25-30% MgO, 70-75% Al2O3, and minimal other species, featuring high porosity with tubular pores oriented perpendicular to the solidification front, and comprising predominantly spinel crystals, is developed to enhance resistance to alkaline corrosion and thermal shocks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If high alumina content refractory products are used, then resistance to high temperatures is improved, but resistance to corrosion by alkaline condensates deteriorates
Solution Approach 1:
The invention changes the chemical composition parameters by adding magnesia (2-10% MgO) to the high alumina refractory product, transforming it from a purely aluminous composition to an alumina-magnesia composite. This parameter change enables the formation of spinel phase which provides dual benefits: maintaining high temperature resistance while significantly improving resistance to alkaline corrosion
Solution Approach 2:
The invention creates a composite refractory material combining alumina and magnesia in specific proportions. The composite structure forms spinel crystals embedded in the refractory matrix, where the spinel phase acts as a protective barrier against alkaline condensate corrosion while the alumina matrix maintains structural integrity at high temperatures
2Reliability
If alumina-magnesia refractory products are formulated with 2-10% magnesia, then resistance to thermal variations is improved, but industrial feasibility deteriorates
Solution Approach 1:
The invention optimizes the magnesia content parameter within a specific range (2-10%) to balance performance and manufacturability. This parameter optimization ensures that the refractory product achieves sufficient thermal shock resistance through spinel formation while maintaining industrial feasibility by avoiding excessive magnesia content that would complicate production and increase costs
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 product exhibits superior resistance to alkaline corrosion and thermal variations, making it suitable for use in regenerators of glass furnaces operating under reducing conditions, with improved feasibility and durability compared to existing products.
Implementation Method 1
The product exhibits superior resistance to alkaline corrosion
Implementation Method 2
featuring high porosity with tubular pores oriented perpendicular to the solidification front
Implementation Method 3
resistance to thermal variations
Data Source
AI summary
The invention provides a fused cast refractory product having the following mean chemical composition by weight, as a percentage by weight based on the oxides:25%<MgO<30%;70%<Al2O3<75%;other species: <1%.The invention is applicable to a regenerator associated with a soda-lime glass fusion furnace operating under reducing conditions.