Wet Refractory Spray Composition for Faster Furnace Turnaround
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Solution Overview
Problem
Existing wet spray materials for firing furnaces require a lengthy drying period after application, leading to increased construction time and costs, and there is a need to improve adherability, fixability, and explosion resistance of the sprayed deposit.
Innovation Solution
A wet spray material comprising refractory raw material with a particle size of less than 1 mm, silica sol as a binder, and a slurry or aqueous solution of specific metal salts as a quick setting agent, with controlled addition rates, is used to enhance adherability, fixability, and curability, while ensuring explosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional wet spray material is used for firing furnaces, then the material can be applied to the construction target surface, but a lengthy drying period of about 50 hours or more is required before the furnace becomes ready for operation
Solution Approach 1:
The patent changes the chemical parameters of the spray material by incorporating specific binders (alumina cement, calcium aluminate cement) and quick-setting agents (calcium chloride, calcium nitrate, magnesium chloride, magnesium nitrate) in controlled amounts. These parameter changes enable the material to set quickly and achieve sufficient strength without requiring lengthy drying periods, reducing the furnace readiness time from 50+ hours to a significantly shorter duration
Solution Approach 2:
The patent creates a composite spray material system combining refractory raw materials (alumina, silica, magnesia) with specific binders and chemical accelerators. This composite formulation works synergistically to provide both rapid setting and adequate structural integrity, eliminating the need for prolonged drying while ensuring the furnace lining is ready for operation
2Ease of manufacture
If conventional wet spray material is used, then the construction process can proceed, but the construction time and costs increase due to the lengthy drying step
Solution Approach 1:
By modifying the chemical composition parameters - specifically adding quick-setting agents like calcium chloride (0.1-5% by mass) and calcium nitrate (0.1-5% by mass) along with appropriate binders - the material achieves rapid setting properties that maintain construction feasibility while dramatically increasing construction speed and productivity
3Loss of time
If the drying step is shortened or omitted, then construction time and costs are reduced, but the adherability, fixability, and explosion resistance of the sprayed deposit may be compromised
Solution Approach 1:
The patent carefully controls the parameters of binder content (3-15% by mass of alumina cement or calcium aluminate cement) and quick-setting agent concentrations to achieve the right balance: enough chemical binding to ensure adherability and explosion resistance, but not so much that it requires lengthy drying. The specific ratio of binders to refractory materials is optimized to provide structural integrity rapidly
Solution Approach 2:
The binders and quick-setting agents act as intermediary substances that facilitate rapid bonding between the spray material and the construction target surface. These intermediaries create strong chemical bonds that provide both adherability and explosion resistance without requiring the sprayed deposit to undergo prolonged drying, thus maintaining reliability while reducing drying time
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 solution allows for the omission or significant reduction of the drying step, reducing construction time and costs, and minimizing fuel consumption, thereby lowering energy costs and CO2 emissions.
Implementation Method 1
add, to the refractory raw material, silica sol, as a binder
Implementation Method 2
add a slurry or aqueous solution of at least one or more selected from among metal salts, specifically from the group consisting of calcium hydroxide, magnesium hydroxide, calcium chloride, potassium chloride, magnesium chloride, sodium chloride, calcium sulfate, potassium sulfate, sodium sulfate, calcium nitrate, magnesium nitrate, sodium nitrate, and potassium nitrate, as a quick setting agent
Data Source
AI summary
A wet spray material for a firing furnace, which is capable of shortening a time until the firing furnace becomes ready for operation after spraying onto a construction target surface of the firing furnace, and a construction method using the wet spray material. Specifically, a refractory raw material comprising 55% by mass to 90% by mass of particles having a particle size of less than 1 mm is kneaded with silica sol and water added thereto, and the resulting kneaded material is pressure-fed to a nozzle, and, after adding thereto a slurry or aqueous solution of at least one or more selected from the group consisting of calcium hydroxide, magnesium hydroxide, calcium chloride, potassium chloride, magnesium chloride, sodium chloride, calcium sulfate, potassium sulfate, sodium sulfate, calcium nitrate, magnesium nitrate, sodium nitrate, and potassium nitrate, in or just before the nozzle, sprayed onto a construction target surface.