Refractory Mix for Copper Melts Resisting Sulfate Attack
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Solution Overview
Problem
Refractory products used in non-ferrous metal melting, particularly copper melting, lack adequate resistance to fayalitic slags and sulfates, and have insufficient high-temperature anti-wetting properties and penetration resistance against hot non-ferrous metal melts.
Innovation Solution
A refractory mix comprising over 90% by weight of olivine raw material, magnesia flour, and silicon carbide flour, with finely divided silica, and optional antioxidants, forming magnesium silicate hydrate phases upon hydration, which enhances resistance to sulfates and non-ferrous metal melts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If magnesia chromite products are used for refractory lining, then basic refractory properties are provided, but resistance to sulfate attack and penetration resistance against hot non-ferrous metals are insufficient
Solution Approach 1:
The patent uses a composite refractory material consisting of magnesia chromite base material combined with forsterite (Mg2SiO4) and silicon carbide (SiC). This composite structure provides both the basic refractory properties from magnesia chromite and the additional resistance to sulfate attack and metal penetration from forsterite and SiC, which form a chemically resistant matrix that prevents sulfate infiltration and metal wetting.
Solution Approach 2:
The patent modifies the chemical composition parameters by adding specific amounts of forsterite (10-30 wt%) and silicon carbide (5-15 wt%) to the magnesia chromite mixture. These parameter changes transform the material properties to achieve high-temperature stability, sulfate resistance, and anti-wetting characteristics against non-ferrous metal melts.
2Temperature
If conventional refractory materials are used, then basic high-temperature stability is achieved, but anti-wetting properties against non-ferrous metal melts are insufficient
Solution Approach 1:
The patent creates local quality differences by incorporating silicon carbide particles distributed throughout the magnesia chromite-forsterite matrix. The SiC particles create localized regions with high chemical inertness and low surface energy that specifically resist wetting by non-ferrous metal melts, while the bulk material maintains its high-temperature stability through the magnesia chromite-forsterite composite structure.
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 products exhibit improved penetration resistance and sulfate resistance at operating temperatures, with increased cold compressive strength and resistance to fayalitic slags, making them superior to previous refractory products in the sector.
Implementation Method 1
forming magnesium silicate hydrate phases upon hydration
Implementation Method 2
forming magnesium silicate hydrate phases
Implementation Method 3
resistant to attack in situ fayalitic slags
Implementation Method 4
penetration resistance against hot non-ferrous metals
Implementation Method 5
high-temperature anti-wetting properties
Data Source
AI summary
The invention relates to a batch made of refractory mineral materials for lining of assemblies used for nonferrous metal melts, containing over 90% by weight of a mixture of the following constituents or very preferably consisting of the following constituents:- from 3 to 74 % by weight of at least one coarse-grain raw olivine material with at least 70% by weight forsterite content and having grain sizes of 50% by weight over 0.1 mm - from 25 to 49% by weight of at least one ground magnesia with grain sizes of 50% by weight ≤ 1 mm - from 0.9 to 14% by weight of at least one ground silicon carbide (SiC) with grain sizes of 50% by weight ≤ 1 mm - from 0.1 to 10% by weight of at least one fine-particle dry pulverulent silica with particle sizes ≤ 500 μm - from 0 to 4% by weight of at least one antioxidant known per se for refractory products - from 0 bis 4% by weight of at least one additional granulated refractory raw material knowon per se, more particularly having grain sizes of 0% by weight, in particular of 80% by weight, preferably of 100% by weight over 0.1 mm - from 0 to 2% by weight of at least one additive known per se for the production of refractory products from batches - from 0 to 4% by weight of at least one additional substance known per se made of ground refractory materials and/or in the form of what is known as medium-grain-size material and/or of what is known as coarse-grain-size material - from 0 to 10% by weight of at least one binder known per se for refractory materials, e.g. in dry form or in ancillary packaging in liquid form.The invention further relates to the use of the batch for producing refractory products.