Magnesia Refractory Batch Composition for Erosion Resistance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing refractory ceramic products used for applications like gunning, tundish, ramming, and backfill require high refractoriness and resistance to erosion and corrosion, but they often suffer from porosity issues and degradation at high temperatures due to the use of binding agents and low-melting point components.
Innovation Solution
A batch composition comprising 55% to 95% magnesia-based raw materials and 5% to 45% magnesite-based raw materials with low total calcium carbonate content (<10%), which dissociates into reactive MgO at high temperatures, forming a dense, refractory, and porous structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If large quantities of binding agents or low-melting point components are added to the batch to improve sinterability and form a refractory binder matrix, then the refractoriness of the product deteriorates because these components sink at service temperatures (1400°C to 1700°C)
Solution Approach 1:
The invention extracts and eliminates low-melting point components and binding agents from the batch composition. By using a pure magnesia-based batch without additives, the patent removes the source of the problem (components that sink at service temperatures) while still achieving sinterability through the inherent properties of magnesia and the sintering process itself.
Solution Approach 2:
The invention changes the chemical composition parameters of the batch by using exclusively high-melting point magnesia-based raw materials. This parameter change ensures that all components in the batch maintain their structural integrity at service temperatures of 1400°C to 1700°C, eliminating the sinking phenomenon while preserving sinterability through optimized firing conditions.
2Object-affected harmful factors
If binding agents are used to form a dense matrix for erosion and corrosion resistance, then the porosity required for good insulation in tundish applications is reduced
Solution Approach 1:
The invention applies local quality by creating different density zones within the refractory product. The magnesia particles form a dense, erosion-resistant framework in contact with slag, while the interparticle spaces maintain porosity for insulation. This spatial differentiation of density allows simultaneous achievement of both erosion resistance and thermal insulation.
Solution Approach 2:
The invention creates a composite structure where magnesia particles of different sizes and morphologies are combined. The composite nature of the magnesia aggregate provides both dense packing for erosion resistance and interparticle voids for porosity, eliminating the need for separate binding agents that would compromise porosity.
3Temperature
If conventional batches with binding agents are used to achieve high refractoriness, then the wear properties (erosion and corrosion resistance) are improved, but the manufacturing complexity increases due to the need for multiple components and precise composition control
Solution Approach 1:
The invention makes magnesia serve multiple functions simultaneously: it provides the refractory framework, acts as the binding phase through direct bonding, ensures erosion and corrosion resistance, and maintains porosity for insulation. This multi-functionality of a single material system eliminates the need for multiple specialized components, simplifying the batch composition while achieving all required performance characteristics.
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 resulting fired refractory ceramic products exhibit excellent wear properties, refractoriness, and insulation, with enhanced resistance to erosion, corrosion, and acidic slags, maintaining structural integrity at service temperatures.
Implementation Method 1
the magnesite-based raw materials of the batch of the invention consist primarily of magnesium carbonate (MgCO3). Beyond a service temperature of approximately 600° C. when using the batch of the invention, the magnesium carbonate of the raw magnesite material dissociates into MgO and CO2.
Implementation Method 2
injection and tundish masses should also form a highly refractory binder matrix... products produced from gunning masses must form a dense matrix against erosion and corrosion. The porosity of linings produced from tundish masses must be high in order to obtain good insulation in this manner and thus to reduce heat losses in the tundish.
Data Source
AI summary
Exemplary embodiments relate to a batch for producing an unshaped refractory ceramic product, to a method for producing a fired refractory ceramic product, to a fired refractory ceramic product and to the use of an unshaped refractory ceramic product.