Castable Refractory Composition Without Hydrogen Emission
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Solution Overview
Problem
Refractory materials that emit hydrogen gas during setting pose safety concerns due to the risk of explosions, but eliminating hydrogen emission reduces their ability to dry out quickly and be installed on hot substrates, compromising their thermal and installation properties.
Innovation Solution
A castable refractory composition comprising 5-95% alumina or aluminosilicate, up to 70% silicon carbide, 1-10% carbon, 0.5-5% alkaline earth metal oxide, and 0.1-5% silica with a surface area of at least 10 m^2/g, which sets without significant hydrogen gas emission, ensuring quick and safe dry-out and high mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If reactive metallic components are added to produce hydrogen gas during setting, then gas permeability and dry-out capability are improved, but safety deteriorates due to explosion risk
Solution Approach 1:
The patent removes reactive metallic components (aluminum, silicon, magnesium) that generate hydrogen gas during setting, thereby eliminating the explosion hazard while maintaining the refractory's functional performance through alternative non-reactive formulations
Solution Approach 2:
The patent changes the chemical composition parameters by substituting reactive metals with non-reactive alternatives, achieving the same permeability and dry-out capabilities through different compositional parameters that do not produce hydrogen gas
2Object-affected harmful factors
If reactive metallic components are eliminated to improve safety, then explosion risk is reduced, but gas permeability and dry-out capability deteriorate
Solution Approach 1:
The patent introduces alternative components and mechanisms that serve as intermediaries to achieve gas permeability and dry-out capability without relying on hydrogen-generating reactive metals, such as using non-reactive aggregates and binders with controlled porosity
Solution Approach 2:
The patent employs composite material formulations combining non-reactive aggregates, binders, and additives to create a refractory composition that achieves the desired permeability and dry-out performance through synergistic interactions of its components rather than through hydrogen gas generation
3Productivity
If conventional reactive metallic components are used, then gas permeability is improved, but installation complexity increases due to safety precautions required
Solution Approach 1:
The patent removes the source of safety concerns (reactive metallic components) from the formulation, thereby eliminating the need for special safety precautions, handling procedures, and ignition source control measures during installation
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 refractory composition achieves safe and rapid dry-out, high gas permeability, and mechanical strength, preventing cracks and explosions, while maintaining installation efficiency on hot substrates without the need for special chemicals or colloidal suspensions.
Implementation Method 1
0.5% to 5% by weight alkaline earth metal oxide and/or hydroxide, and 0.1% to 5% by weight of silica having a surface area of at least 10 m2
Data Source
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AI summary
Castable refractory compositions, refractory linings and articles formed therefrom and methods of installing a refractory from said castable refractory composition.