Silicate Ester Binder Wear Lining for Ladles
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Solution Overview
Problem
Current wear linings for casting ladles and pouring boxes rely on organic binders like phenol formaldehyde resins, which pose health risks and environmental disposal challenges, and existing inorganic binder methods are complex and costly, with issues in achieving uniform hardening and mechanical strength.
Innovation Solution
A process using a pourable mass of particulate refractory materials with sodium or potassium silicate and esters, where the binder is added simultaneously with the material delivery, allowing for ester-based hardening to form a silica-containing gel, potentially combined with CO2-based hardening for enhanced uniformity and mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If organic binders like phenol formaldehyde resins are used, then the wear lining achieves sufficient binding strength, but health risks and environmental disposal problems occur
Solution Approach 1:
The invention changes the chemical composition parameters of the binder system by using sodium or potassium silicate instead of organic phenol formaldehyde resins. This substitution maintains the binding function while eliminating the harmful organic components, directly resolving the contradiction between achieving sufficient binding strength and avoiding health/environmental hazards
Solution Approach 2:
The patent employs a binder system based on sodium or potassium silicate that can be easily applied and sets rapidly. The binder formulation allows for a simpler, more environmentally friendly composition that achieves its binding purpose without the persistent environmental issues of organic resins, effectively replacing harmful long-lasting materials with safer alternatives
2Object-affected harmful factors
If existing inorganic binder methods are used, then environmental friendliness is improved, but the production process becomes complex and costly
Solution Approach 1:
The invention merges the binder addition step with the material delivery process. The sodium or potassium silicate binder is introduced simultaneously with the particulate refractory material in a single integrated operation, eliminating separate mixing and application steps. This consolidation simplifies the production process while maintaining environmental friendliness through inorganic binder usage
Solution Approach 2:
The binder system utilizes the natural properties of sodium or potassium silicate to self-set and form a cohesive wear lining without requiring complex additional processing equipment or multi-step procedures. The material essentially binds itself through the chemical properties of the silicate binder, reducing production complexity
3Object-affected harmful factors
If existing inorganic binder methods are used, then environmental friendliness is improved, but uniform hardening and mechanical strength are compromised
Solution Approach 1:
The invention ensures continuous and uniform distribution of the sodium or potassium silicate binder throughout the particulate refractory material during the simultaneous addition process. This continuous mixing and binding action ensures uniform hardening throughout the wear lining, eliminating the non-uniformity issues that plague traditional inorganic binder methods while maintaining environmental friendliness
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
This method simplifies the production process, reduces costs, and achieves a tough, well-adhered wear lining with improved mechanical strength and thermal insulation, while being environmentally friendlier by eliminating the need for hazardous organic binders.
Implementation Method 1
contains a binder in the form of at least 4 wt-% of sodium silicate or potassium silicate and an ester or a mixture of esters, this binder being capable of converting the said silicate into a silica-containing gel, which binds the particulate refractory material into a solid substance
Implementation Method 2
the binder consisting of the said silicate and ester is added to the particulate refractory material in one mixing step simultaneously with the delivery of the latter to the required position to be lined
Data Source
Figure 1
AI summary
The present invention relates to a process for making a wear lining for casting ladles and pouring boxes used in foundries, in which process the wear lining is formed by introducing into a casting ladle or pouring box a pourable mass consisting of a granular or particulate refractory material that has a low heat conductivity and contains at least 4 wt-% of sodium silicate or potassium silicate and which binds together to form a solid mass in situ by means of a silica- containing gel precipitated from the silicate by the addition of a suitable ester or mixture of esters, optionally combined with the introduction of carbon dioxide. The invention also relates to a process for increasing the service life of the wear lining made in this way by adapting its MgO content according to whether it - the lining - comes into contact mainly with molten metal or molten slag.