Silica-Based Refractory Block Using P2O5 Binder
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Solution Overview
Problem
Existing precast refractory blocks for coke ovens face challenges in maintaining high hot strength and stable under-load expansion/shrinkage behavior at high temperatures, with issues such as hydration reactions from cement and deterioration in hot strength when using colloidal silica and silicate soda as binders.
Innovation Solution
Incorporating a P2O5 component as a binder in a silica-based precast refractory block, within a specific range of 0.3 to 2.0 mass%, to stabilize under-load expansion/shrinkage behavior while maintaining high hot strength, replacing traditional cement or colloidal silica and silicate soda binders.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If Portland cement is used as a binder in a large amount (2 to 10 weight%), then the precast refractory block can be formed, but the precast refractory block largely shrinks under a load at high temperatures due to hydration reaction of Portland cement
Solution Approach 1:
The invention changes the chemical composition parameters by limiting Portland cement to 0.1-5% and introducing specific oxide components (Al2O3: 5-30%, CaO: 5-20%, MgO: 5-15%) to replace cement as the primary binder, thereby eliminating hydration-induced shrinkage while maintaining binding capability
Solution Approach 2:
The invention creates a composite refractory material system combining silica base material with multiple oxide components (Al2O3, CaO, MgO, Fe2O3, TiO2, etc.) that work synergistically to provide binding strength without the harmful hydration reactions of Portland cement
2Stability of the object's composition
If colloidal silica and silicate soda are used as a binder, then under-load shrinkage at high temperatures is suppressed, but hot strength deteriorates
Solution Approach 1:
The invention replaces colloidal silica and silicate soda with a composite oxide system (Al2O3, CaO, MgO, Fe2O3, TiO2, etc.) that provides both binding capability and high-temperature strength through refractory mineral phases rather than glassy binders
Solution Approach 2:
The invention changes the binder composition from silica-based colloidal systems to an oxide-based refractory system with controlled ratios of Al2O3 (5-30%), CaO (5-20%), and MgO (5-15%) to achieve both dimensional stability and high hot strength
3Ease of manufacture
If silica brick is used for lining, then the lining can be constructed, but a large number of silica bricks are required, requiring time for the construction
Solution Approach 1:
The invention segments the lining construction into precast blocks that can be manufactured off-site and installed quickly, reducing on-site construction time while maintaining the required lining performance
Solution Approach 2:
The invention merges multiple silica bricks into a single precast block structure, reducing the total number of individual units to be handled and installed, thereby significantly reducing construction time
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 enables a precast refractory block with high hot strength and stable under-load expansion/shrinkage behavior at high temperatures, preventing deformation and enhancing the push-out operation resistance in coke ovens.
Implementation Method 1
using a P 2 O 5 component as a binder component
Implementation Method 2
stabilization of an under-load expansion behavior and an under-load shrinkage behavior at high temperatures
Data Source
Figure 1
AI summary
The present invention provides a precast refractory block for a coke oven having high hot strength and stable under-load expansion/shrinkage behavior at high temperatures. Specifically, the present invention provides a silica-based precast refractory block for a coke oven, wherein the precast refractory block contains a P2O5 component in an amount of 0.3 to 2.0 mass%.