Refractory Binder System for Blast Furnace Taphole
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Solution Overview
Problem
Conventional refractory aggregate systems for taphole closure in blast furnaces face challenges in maintaining the right consistency across a wide temperature range, as they become too stiff at lower temperatures and cure prematurely at higher temperatures, leading to issues like 'short taphole' and difficulty in application, and aqueous systems can be hazardous and exhibit unstable viscosity.
Innovation Solution
A non-aqueous refractory formulation using a low viscosity anhydrous liquid and an oleophilic rheology modifier, such as organoclay, which interacts with the liquid to create a viscoplastic material with reduced thermoplastic behavior, allowing for consistent application and formability across a broader temperature range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional tars, pitches, or resins are combined with large amounts of fine particulates to increase fluid friction and create viscous thermoplastic material, then the material can be applied through mud gun equipment, but the material exhibits highly thermoplastic behavior with large viscosity changes as temperature changes, making it difficult to maintain proper consistency across temperature ranges
Solution Approach 1:
The patent changes the fundamental parameters of the binder system by replacing conventional thermoplastic tars, pitches, and resins with a synthetic polymer binder that exhibits viscoplastic behavior. This parameter change in material selection fundamentally alters the temperature-viscosity relationship, maintaining stable consistency across a broader temperature range while preserving mud gun applicability.
Solution Approach 2:
The patent creates a composite refractory material system combining synthetic polymer binder with refractory aggregates and fine particulates. This composite approach integrates materials with complementary properties: the synthetic polymer provides viscoplastic stability, while the particulates provide structural integrity and controlled fluid friction for mud gun application.
2Adaptability or versatility
If large quantities of very fine particles are added to increase the useful range of plasticity in conventional formulations, then the plasticity range is extended, but channels between particles are constricted making it more difficult for gases of pyrolyzation to escape
Solution Approach 1:
The patent changes the binder type from conventional thermoplastic materials to synthetic polymer, which provides extended plasticity range through different mechanisms. This allows adequate gas escape channels to be maintained while still achieving the required plasticity versatility, as the synthetic polymer does not rely on fine particle constriction for plasticity control.
3Ease of operation
If coal tar and coal tar pitch or petroleum tar and petroleum pitch and phenolic resin are used as binding system to develop plasticity when heated, then the material becomes soft and clay-like at application temperature, but the material starts to cure due to evaporation of volatiles, polymerization, or carbonization at upper temperature limit
Solution Approach 1:
The patent changes the binder chemistry from conventional tar/pitch/resin systems to synthetic polymer binders. This parameter change eliminates the premature curing issue by using polymers with higher thermal stability and controlled curing characteristics, while maintaining the desired soft clay-like consistency at application temperatures through polymer rheology control.
4Stability of the object's composition
If aqueous systems are used to develop viscoplasticity in refractory systems, then water provides low viscosity and low thermoplastic nature, but the system exhibits large change in plasticity with small change in liquid content and may react explosively with iron
Solution Approach 1:
The patent changes the liquid phase from aqueous to organic-based synthetic polymer system. This parameter change eliminates explosive reactions with iron by using non-aqueous, non-reactive binder chemistry, while maintaining stable viscoplasticity through polymer molecular structure and interparticle interaction control.
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 formulation maintains plasticity and formability from -10°C to 100°C, with consistent extrusion pressure across varying liquid content, reducing the risk of premature curing and 'short taphole' issues, and allows for effective use in high-temperature applications up to 1540°C.
Implementation Method 1
A non-aqueous refractory formulation using a low viscosity anhydrous liquid and an oleophilic rheology modifier, such as organoclay, which interacts with the liquid to create a viscoplastic material with reduced thermoplastic behavior
Implementation Method 2
an oleophilic rheology modifier, such as organoclay, which interacts with the liquid to create a viscoplastic material
Implementation Method 3
A non-aqueous refractory formulation using a low viscosity anhydrous liquid and an oleophilic rheology modifier
Implementation Method 4
create a viscoplastic material with reduced thermoplastic behavior, allowing for consistent application and formability across a broader temperature range
Data Source
AI summary
A refractory formulation containing an anhydrous solvent, an oleophilic rheology modifier and a refractory aggregate exhibits non-thermoplastic behavior, and remains plastic and formable at temperatures in the range of 10 degrees Celsius to 180 degrees Celsius. The oleophilic rheology modifier may effectively bind with the solvent to create a gel-like structure with organic solvents with moderate to high polarity. A phyllosilicate clay that has been treated with a quaternary fatty acid amine may be used as the oleophilic rheology modifier.