Spray-Applied Fireproof Coating from Recycled Refractory Waste
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Solution Overview
Problem
The recycling rate of waste refractory materials from steel mills is low, leading to resource wastage and quality degradation issues in the construction and civil engineering sectors.
Innovation Solution
A Spray applied fireproof covering composition that recycles amphoteric waste refractory materials by incorporating them as refractory insulating aggregates in a hydraulic refractory mortar, enhancing recycling rates and providing excellent refractory performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If waste refractory materials are recycled as refractory raw material for steelmaking, then the recycling rate is improved, but the application scope is limited and quality degradation issues occur
Solution Approach 1:
The patent transforms waste refractory materials into a multi-functional product that can be used in both steelmaking applications and construction/civil engineering applications. By formulating the waste refractory materials as aggregates in spray-applied fireproof covering compositions, the invention enables these materials to serve dual purposes: maintaining their traditional refractory function while also providing fire protection and structural reinforcement in construction contexts, thereby significantly expanding their application scope.
2Loss of substance
If waste refractory materials are used as refractory insulating aggregates in spray-type hydraulic refractory mortar, then resource conservation is improved, but the composition complexity increases
Solution Approach 1:
The patent systematically optimizes the composition parameters by specifying precise weight percentage ranges for each component: 10-80 wt% waste refractory fine aggregate, 5-55 wt% binder, 5-35 wt% heat-absorbing material, 0.3-1.7 wt% organic fiber, 0.5-3.5 wt% accelerator, 0.1-0.7 wt% thickener, 0.1-0.9 wt% fluidizer, and 0.05-0.15 wt% air-entraining agent. These controlled parameter ranges transform a potentially complex mixture into a standardized, manageable composition that balances resource conservation with practical manufacturability and performance consistency.
3Reliability
If conventional fire-resistant mortar is sprayed onto concrete members, then fire resistance is improved, but the cost increases and spalling protection is insufficient
Solution Approach 1:
The patent converts the harmful waste refractory materials from steel mills into beneficial refractory insulating aggregates for fireproof coatings. By incorporating 10-80 wt% of these recycled aggregates into the mortar composition, the invention simultaneously reduces waste disposal problems while creating a cost-effective fire-resistant coating that also provides spalling protection through the combined effects of the refractory aggregates and heat-absorbing materials.
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 composition effectively recycles waste refractory materials, improving resource conservation and environmental protection, while providing superior fire resistance and structural integrity to concrete and steel structures during high-temperature fires.
Implementation Method 1
5 to 35 wt% of heat-absorbing material
Implementation Method 2
5 to 55 wt% of binder
Implementation Method 3
0.3 to 1.7 wt% of organic fiber
Implementation Method 4
0.5 to 3.5 wt% of accelerator
Data Source
Figure 1a
Figure 1b
Figure 1c
AI summary
The present invention relates to a spray applied fireproof covering composition recycled from non-ferrous waste materials, characterized by comprising: 10 to 80 wt % of non-ferrous waste aggregate; 5 to 55 wt % of binder; 5 to 35 wt % of heat-absorbing material; 0.3 to 1.7 wt % of organic fibers; 0.5 to 3.5 wt % of setting accelerator; 0.1 to 0.7 wt % of thickening agent; 0.1 to 0.9 wt % of fluidity agent; and 0.05 to 0.15 wt % of air-entraining agent (A.E.). By recycling non-ferrous waste bricks, which are primarily disposed of in shared waters after being used as refractory bricks in steel plants, as a major component of the spray applied fireproof covering composition, this invention contributes to resource conservation and environmental protection by reducing waste. Furthermore, it prevents the collapse of structures due to explosive spalling of concrete during fires in construction and civil engineering sites and mitigates the risk of collapse in steel structures under high temperatures. The smaller voids provide excellent thermal insulation at high temperatures, and when applied to damaged areas of existing concrete structures, it exhibits a reinforcing effect through structural strength enhancement.