Silicon Carbide Refractory Block Calcination Coated Layer
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Solution Overview
Problem
Conventional silicon carbide-natured refractory blocks lack sufficient corrosion resistance and durability, especially when exposed to oxidizing atmospheres, limiting their industrial usability and durability in high-temperature applications like blast-furnace industries.
Innovation Solution
A method involving the formation of a calcination coated layer on a silicon carbide-natured refractory block by heating the superficial portion in an oxidizing atmosphere to convert silicon carbide into silicon oxide, enhancing the block's corrosion resistance and mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If silicon carbide-natured refractory blocks are used in oxidizing atmospheres, then they provide good mechanical strength and portability, but they exhibit insufficient corrosion resistance
Solution Approach 1:
The patent applies preliminary action by performing calcination treatment on the refractory block surface before actual use. The surface is pre-oxidized in a controlled manner to form a silicon oxide layer, which serves as a protective barrier against future corrosion. This preliminary protective action prevents the harmful effects of oxidation during service.
Solution Approach 2:
The patent converts the harmful oxidation effect into a beneficial protective mechanism. Instead of preventing oxidation entirely, the invention allows controlled oxidation of the silicon carbide surface to form silicon oxide, which has superior corrosion resistance. The harmful oxidizing atmosphere is thus transformed into a protective coating process.
2Reliability
If the surface layer is made oxidation-resistant through calcination, then corrosion resistance improves, but silicon carbide must be present in sufficient amounts
Solution Approach 1:
The patent applies local quality by concentrating the silicon carbide content specifically in the surface layer where it is needed for calcination. The core material can have different composition, but the surface portion contains sufficient silicon carbide (5-20 mass%) to form the protective silicon oxide layer during calcination treatment, while maintaining overall material performance.
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 calcination coated layer significantly improves the block's corrosion resistance and mechanical strength, particularly against blast-furnace slag and spall resistance, resulting in a more durable refractory block with enhanced performance for industrial applications.
Implementation Method 1
heating an outer superficial portion of the fire-resistant block body to oxidize at least some of silicon carbide therein to turn the silicon carbide into the silicon oxide
Implementation Method 2
Since silicon carbide is oxidized to sinter the calcination coated layer
Data Source
Figure 1
Figure 2~3
AI summary
A silicon carbide-natured refractory block includes a fire-resistant block body, and a calcination coated layer. The fire-resistant block body includes a silicon carbide-natured refractory having a predetermined configuration. The calcination coated layer includes silicon oxide made by heating an outer superficial portion of the fire-resistant block body to oxidize at least some of silicon carbide therein to turn the silicon carbide into the silicon oxide. The silicon oxide sinters the calcination coated layer to increase the corrosion resistance.