Self-levelling Refractory Concrete for Glass Furnace Floors
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Solution Overview
Problem
The glass industry faces challenges in finding a refractory concrete that is pumpable, self-levelling, and free from segregation for glass furnace floors, as existing solutions either require vibration for application or are not suitable due to differences in corrosion conditions between glass and metal smelting furnaces.
Innovation Solution
A powder composition comprising 94-99% refractory materials like alumina, zirconia, and silica, with 1-6% hydraulic cement, 0-0.03% organic fibers, and 0.075-1% surfactant, specifically distributed to ensure particles <40 μm are 29-45% and <10 μm are 16-45% zirconia, making the concrete pumpable and self-levelling without vibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional refractory concrete is used for glass furnace floors, then it provides corrosion resistance, but it is not pumpable with suction pressures of 180 bar or less
Solution Approach 1:
The patent modifies the rheological parameters of the refractory concrete by adding specific chemical admixtures (superplasticizers and air-entraining agents) and controlling the water-cement ratio. These parameter changes enable the concrete to be pumped at suction pressures of 180 bar or less while maintaining its corrosion-resistant properties through careful selection of refractory aggregates and cement composition.
Solution Approach 2:
The patent uses composite refractory materials combining different types of aggregates (corundum, mullite, silica) with hydraulic cements and chemical admixtures. This composite approach allows the concrete to simultaneously achieve pumpability through proper rheological composition and corrosion resistance through the inherent properties of the refractory aggregate mixture.
2Manufacturing precision
If vibration operation is used to lay fresh concrete, then it ensures proper compaction, but it causes segregation and requires lengthy operation
Solution Approach 1:
The patent formulates the refractory concrete with specific rheological properties (viscosity, flowability) achieved through chemical admixtures and particle size distribution control, enabling the concrete to self-compact and self-levell without external vibration. The concrete automatically fills formwork and consolidates under its own weight, eliminating the need for vibration equipment and operators while preventing segregation through proper mix design.
3Stability of the object's composition
If uniform vibration is applied to large areas, then it prevents segregation, but it requires particular know-how and may still result in cracks
Solution Approach 1:
The patent develops a self-compacting refractory concrete formulation that automatically maintains homogeneity and prevents segregation without requiring vibration operations. The specific combination of chemical admixtures, particle size distribution, and water-cement ratio enables the concrete to flow and consolidate uniformly across large areas under its own weight, eliminating the need for operator skill in vibration application and preventing cracks associated with improper vibration.
4Adaptability or versatility
If metal smelting furnace concrete is used for glass furnaces, then it meets metal corrosion conditions, but it generates defects like stone release and bubbles in glass
Solution Approach 1:
The patent selects refractory aggregates with specific local qualities suitable for glass furnace environments, including controlled impurity content, specific mineral compositions (corundum, mullite, silica), and appropriate particle size distributions. This local quality optimization ensures the concrete resists glass corrosion while preventing the generation of harmful defects such as stone release and bubbles that would occur with metal smelting furnace concretes.
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 concrete is pumpable with 180 bar suction pressure, self-levelling, and free from segregation, resulting in a cured product with satisfactory dilatometric behavior suitable for glass furnace floors.
Implementation Method 1
0.075% to 1%, and preferably 0.1% to 1%, of a surfactant
Implementation Method 2
1% to 6%, preferably 3%-5%, of a hydraulic cement
Data Source
AI summary
A powder including, in percentages by weight: (a) 94% to 99% of particles of at least one refractory material, the main constituent(s) of which are alumina and/or zirconia and/or silica; (b) 1% to 6% of a hydraulic cement; (c) 0 to 0.03% of organic fibers; (d) optionally, 0.075% to 1% of a surfactant; and (e) optionally, a setting accelerator, where the fraction of particles having a size below 40 μm being distributed, in percentages by weight relative to the weight of the powder, in the following manner: (1) fraction<0.5 μm: ≧4%, (2) fraction<2 μm: ≧5%, fraction<10 μm: ≧16%, and fraction<40 μm: 29-45%, where the proportion of zirconia in the fraction of particles having a size smaller than 10 μm, called “fines”, is between 35% and 75% by weight relative to the total weight of said fraction.