Lightweight Insulating Composite Refractory for Boiler Liners
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Solution Overview
Problem
Existing refractory materials for thermal insulation in energy equipment are either low in strength and high in thermal conductivity or high in density and low in strength, limiting their effectiveness and longevity, and there is a need for materials that are lightweight, high-strength, and low-thermal conductivity to improve efficiency and reduce environmental impact.
Innovation Solution
A lightweight insulating composite refractory material composed of recycled glass scrap, mineral wool, aluminosilicate microspheres, and inert silicon-based additives, with a controlled hydration process, achieving high compressive strength and low thermal conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional refractory materials are used for thermal insulation, then thermal insulation performance is achieved, but strength is low and density is high
Solution Approach 1:
The patent creates a composite refractory material combining heavy minerals (kyanite, fireclay) with lightweight porous aggregates (expanded perlite, expanded clay). This composite structure achieves high compressive strength (0.8-1.5 MPa at 800°C) while maintaining low density (230-250 kg/m³), resolving the contradiction between strength and weight.
Solution Approach 2:
The patent incorporates porous lightweight aggregates (expanded perlite with 80-90% porosity, expanded clay) into the refractory matrix. These porous materials provide thermal insulation while reducing overall density to 230-250 kg/m³, simultaneously achieving both insulation performance and weight reduction.
2Loss of energy
If porosity is increased to reduce density and thermal conductivity, then insulation performance improves, but strength decreases
Solution Approach 1:
The patent creates a composite refractory material combining heavy minerals (kyanite, fireclay) with lightweight porous aggregates (expanded perlite, expanded clay). This composite structure achieves high compressive strength (0.8-1.5 MPa at 800°C) while maintaining low density (230-250 kg/m³), resolving the contradiction between strength and weight.
Solution Approach 2:
The patent optimizes the porosity parameter of the lightweight aggregates (80-90% for expanded perlite) and controls the water-cement ratio (0.4-0.6) to achieve the right balance between thermal insulation and mechanical strength, allowing the material to withstand high temperatures while maintaining structural integrity.
3Strength
If high density materials are used to increase strength, then compressive strength improves, but thermal conductivity increases and insulation performance worsens
Solution Approach 1:
The patent creates a composite refractory material combining heavy minerals (kyanite, fireclay) with lightweight porous aggregates (expanded perlite, expanded clay). This composite structure achieves high compressive strength (0.8-1.5 MPa at 800°C) while maintaining low density (230-250 kg/m³), resolving the contradiction between strength and weight.
Solution Approach 2:
The patent assigns different functions to different components: heavy minerals (kyanite, fireclay) provide structural strength and refractory properties, while lightweight porous aggregates (expanded perlite, expanded clay) provide thermal insulation. This local specialization of material properties allows the composite to achieve both high strength and low thermal conductivity simultaneously.
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 up to 4 times higher compressive strength and 2.8 times lower density after thermal treatment, maintaining structural integrity and thermal insulation at high temperatures, with improved mechanical and physical properties.
Implementation Method 1
aluminosilicate-based waste from the mineral stone wool production process with pozzolanic properties
Implementation Method 2
inert (amorphous silicon-based) and lightweight aggregates made from used glass waste with a density of 670-800 kg/m3
Implementation Method 3
The porosity of such materials should be greater than >45%
Implementation Method 4
calcium aluminate cement
Data Source
Figure 1~2
Figure 3
AI summary
This invention discloses a lightweight insulating composite refractory using recycled and reusable materials. The following raw materials are suitable for the production of the material with the required properties: aluminous cement, aluminosilicate microspheres, dispersed chamotte filler, light blown glass filler made from glass waste, pozzolanic stone mineral wool production process waste, inert amorphous silicon-based additive and hydration process additive carbonate based. The new concrete, after drying and heat treatment at high temperatures, is lighter and stronger than other refractory concretes with vermiculite, perlite and other lightweight aggregates. It is also important to improve the physical, insulating, performance, mechanical properties of refractory insulation material and to reduce shrinkage. This lightweight refractory material is particularly useful as the protective layer of boiler liners and for the thermal insulation of other energy equipment types.