Refractory material and product thereof containing low-silica electrofused magnesia clinker

FIELD OF ART
The present invention relates to a refractory material of magnesia clinker and to an application thereof.
BACKGROUND OF THE INVENTION
Magnesia-carbon bricks composed mainly of MgO have been in general use as a lining material for converters and stainless steel manufacturing furnaces on account of their good spalling and slag resistance.
They are still subject to slag attack when used in an environment where the refining temperature is higher and secondary combustion prevails. This results in the dissolution of the magnesia clinker in slag, leaving the carbon, such as graphite, in bricks always exposed with the surfaces of the bricks. This accelerates the carbon oxidation and, hence, the rate of corrosion.
A conventional way to protect graphite in magnesia-carbon bricks from oxidation is the addition of an antioxidant of a readily oxidizable metal to the brick constituents.
However, an additional antioxidant alone is not enough to prevent the dissolution and oxidation of decarburization layer resulting from a slag attack in refining furnaces operating at 1700.degree. C. or above.
Concerning the improvement of slag corrosion resistance at high temperatures, Japanese Patent Publication No. Sho 54-8206 discloses that electrofused magnesia is superior to sintered magnesia in resistance to corrosion by molten metal and slag when used as a raw material in refractories for steel and non-ferrous metal melting furnaces, because of its power crystal boundaries where mechanical destruction and chemical corrosion begin.
As a raw material of filler for lining refractories for steel and nonferrous metal melting furnaces, electrofused magnesia is used in the form of a grain having a size of 5 to 3 mm, 3 to 1 mm, or 1 to 0 mm, obtained by crushing clinker ingots, which are subjected to classification and particle size regulation.
For electrofused clinker to be a strong filler for refractories, the electrofused magnesia should include a high ratio of single crystal. Clinker ingot with a large ratio of single crystal can be obtained by melting from high-purity magnesia containing more than 99.9 wt. % of MgO. However, this kind of high-purity magnesia is too expensive to be used as a refractory material, so its use is limited to optical windows and electronic device substrates.
A possible means to obtain electrofused magnesia with a high ratio of single crystal is by the electrofusion of a relatively less pure raw material containing 99.0 to 99.8 wt. % of magnesia to obtain clinker ingots from which large crystals are selectively chosen. However, this method is deemed impractical because of low yields.
Meanwhile, it is known that electrofused magnesia used as a filler of refractories exhibits good corrosion resistance because CaO crystallizes out at the grain boundary of the periclase crystal having a high CaO/SiO.sub.2 ratio and reacts with slag to increase its viscosity, thereby preventing its infiltration into the grain boundary.
However, electrofused magnesia with a high CaO/SiO.sub.2 ratio has the disadvantage of limiting the growth of single crystal by increased impurities. Moreover, the addition of CaO to electrofused magnesia poses a problem associated with the slaking of CaO which deteriorates the structure of refractories.
It is an object of the present invention to provide electrofused magnesia clinker having a high ratio of single crystal which is obtained from a raw material of comparatively low purity which has never before been thought to be usable as well as a refractory material of electrofused magnesia having a high CaO/SiO.sub.2 ratio.
It is another object of the present invention to provide a refractory material containing electrofused magnesia clinker which is stable against slag attack and especially has high corrosion resistance against slag with a high iron content, even in an oxidative environment at high temperatures.
It is yet another object of the present invention to provide a refractory material of electrofused magnesia clinker which poses no problems associated with the slaking of CaO when the electrofused magnesia material contains CaO for improving corrosion resistance through the ability of CaO to prevent the infiltration of slag into the grain boundary.
It is a further object of the present invention to provide a burned or unburned refractory brick or a prepared unshaped refractory of good Corrosion and spalling resistance which is produced from highly corrosion-resistant electrofused magnesia clinker.
DISCLOSURE OF THE INVENTION
In general, magnesia clinker in magnesia-carbon bricks begins to deteriorate upon deterioration at the grain boundary. Namely, a foreign matter infiltrates inside of the brick by infiltration of silicate or silicate containing iron oxide into the grain boundary, which accelerates the following reaction to magnesia to form a low-melting material, leading to the disintegration of bricks.
2MgO+SiO.sub.2 .fwdarw.2MgO.multidot.2SiO.sub.2
MgO+FeO.fwdarw.(Mg, Fe)O
It was found that impurities hinder the growth of periclase crystals generating as the temperature of molten magnesia goes down in the production of electrofused magnesia clinker. Particularly, MgO is the most important factor to inhibit the crystal growth. This finding led to the idea of using magnesia clinker having a higher ratio of single crystal than ordinary magnesia clinker produced from high-purity magnesia. Using magnesia clinker having a higher ratio of single crystal prevents the deterioration at the grain boundaries and the formation of low-melting materials which cause the disintegration of bricks.
The present invention is embodied in a refractory material of electrofused magnesia clinker containing 98.0 to 9.8 wt. % of MgO, less than 0.05 wt. %, preferably less than 0.02 wt. %, more preferably less than 0.01 wt. % of SiO.sub.2, and 0.1 to 2.0 wt. % of CaO, with the CaO/SiO.sub.2 ratio being high, and also having a markedly high ratio of single crystal in grains of ordinary size for refractory use.
According to the present invention, this electrofused magnesia clinker can be made into burned or unburned refractory bricks with good corrosion resistance upon incorporation with more than 10 wt. % of other refractory materials.
SiO.sub.2 contained with CaO in the electrofused magnesia material forms CaO-SiO.sub.2 compounds in the early stages of the production of electrofused magnesia material, reducing the effectiveness of the free CaO which should prevent the infiltration of slag into the crystal grain boundary.
Moreover, the presence of CaO in an electrofused magnesia material cannot exhibit the effective function in periclase crystals. In other words, CaO effectively operates when reacting with slag which is infiltrating into the grain boundary. Therefore, the presence of CaO should be concentrated into the crystal grain boundary.
In order to concentrate CaO into the crystal grain boundary, when periclase crystals crystalize from molten magnesia for producing an electrofused magnesia material, the periclase crystals should be purified driving CaO, as impurities, toward the crystal grain boundary.
The inventors of the present invention found that the presence of SiO.sub.2 is the most important factor to prevent the pure growth of periclase crystals. In the present invention, reduction of the SiO.sub.2 content provides the refractory materials in which CaO can be concentrated into the crystal grain boundary, and further provides a burned or unburned refractory brick as well as unshaped refractory for pouring or stamp use.
In addition thereto, according to the present invention, the low SiO.sub.2 content promotes the pure growth of periclase crystals, giving rise to electrofused magnesia ingots having a much larger crystal size than ordinary ones of the same magnesia content.
The high ratio of single crystal means the presence of fewer grain boundaries where mechanical disruption and chemical corrosion take place. This leads to improved corrosion resistance against slag and molten metal. In addition, the high CaO/SiO.sub.2 ratio drives CaO out of the periclase crystals to the grain boundary of the polycrystalline electrofused magnesia filler. The CaO on the grain boundary reacts with slag, increasing its viscosity, to prevent its infiltration into the crystals. This also leads to improved corrosion resistance.
According to the present invention, the electrofused magnesia should contain 98.0 to 99.8 wt. % of MgO. With an MgO content below 98.0 wt. %, the electrofused magnesia will relatively contain too many impurities to allow the smooth growth of periclase crystals from molten magnesia. Hence the resulting electrofused magnesia lacks its fundamental characteristic properties owing to insufficient crystal size. With an MgO content more than 99.8 wt. %, the electrofused magnesia will not contain a sufficient amount of CaO.
According to the present invention, the electrofused magnesia should contain less than 0.05 wt. % of SiO.sub.2. Otherwise, the excess SiO.sub.2 will react with CaO to form CaOSiO.sub.2 compounds in the early stages of the production of electrofused magnesia. This reaction decreases the amount of free CaO to be driven to the grain boundary where it will prevent the infiltration of slag. Therefore, the SiO.sub.2 content should be as low as possible, preferably, lower than 0.03 wt. %, more preferably lower than 0.02 wt. %.
According to the present invention, the electrofused magnesia should contain 0.1 to 2.0 wt. % of CaO. CaO in an amount below 0.1 wt. % will not be enough to prevent the infiltration of slag into the grain boundary through its reaction with slag which causes slag to increase in viscosity. In addition, such a small amount of CaO is insufficient to form MgO.CaO which exists as a solid solution in the low temperature range from room temperature to 700.degree. C., and CaO phase is crystalized in periclase structure, leading to poor resistance of the grain itself against thermal shocks. The desirable CaO content is from 0.2 wt. % to 1.0 wt. %. With a CaO content in excess of 2.0 wt. %, the electrofused magnesia will have poor corrosion resistance because CaO functions as an undesirable impurity. In addition, excess CaO hinders the growth of periclase crystals during the production of clinker. An adequate amount of CaO in the specified range does not pose any problems associated with slaking.
According to the present invention, the electrofused magnesia may be incorporated with a variety of refractory materials, including carbonaceous powder such as natural or artificial graphite, coke, mesophase carbon, carbon black, and diamond powder, ordinary magnesia clinker, electrofused maglime clinker containing 1.5 to 40 wt. % of CaO, other sintered clinker, dolomite clinker filler, and a refractory material selected from zirconia, zircon, alumina, silica, chromium mineral, silicon carbide, BN, and B.sub.4 C as well as any combination thereof.
Among them, the incorporation of industrial diamond powder into the appropriate working portion of the refractories can lead to the best use of the mechanical advantage of diamond such as high oxidation resistance, high hardness and high strength. Thus, the finished bricks containing industrial diamond powder are desirable to be used for the refractories for controlling flows such as the tuyere and sliding nozzle which require high oxidation and wear resistance.
The magnesia clinker to be used as a filler in the present invention may be obtained by electrofusing a raw material of magnesia such as sintered magnesia, calcined magnesia, magnesium hydroxide, and magnesium carbonate. These refractory raw materials should preferably have as high a degree of crystallinity as possible. These raw materials may also be incorporated with pitch or phenolic polymer resin powder to improve spalling resistance.
The electrofused magnesia is made into refractory bricks with the aid of a binder selected from phenolic resin, furan resin, epoxy resin, modified phenolic resin, melamine resin, and urea resin. A phenolic resin or modified phenolic resin is more desirable from the view point of residual carbon and price.
The refractory bricks may be incorporated with a powder of metal or alloy thereof such as Al, Si, Ca, Cr, Mg, and B to improve the oxidation resistance, corrosion resistance, and high temperature strength.
Magnesia clinker of the above-mentioned composition will exhibit its effect regardless of the type of refractory materials--carbon-free burned and unburned bricks, carbon-containing burned and unburned bricks, and prepared unshaped refractories.
Incidentally, the amount of carbonaceous powder to be incorporated into the refractory bricks should be from 3 wt. % to 40 wt. %. An amount below the lower limit will not be enough to produce satisfactory spalling and slag resistance. An amount in excess of the upper limit will result in difficulty in mixing, poor operation and low oxidation resistance.

DESCRIPTION OF THE PREFERRED EMBODIMENT
EXAMPLE 1
Table 1 shows the various characteristics of electrofused magnesia prepared from different raw materials. Each electrofused magnesia was prepared from ordinary sintered raw materials in different ratios and electrofused.
TABLE 1__________________________________________________________________________Composition Composition ofof raw material (wt. %) electrofused magnesia (wt. %) Ratio of single crystal inMgO CaO SiO.sub.2 B.sub.2 O.sub.3 MgO CaO SiO.sub.2 B.sub.2 O.sub.3 electrofused magnesia (%)__________________________________________________________________________1A 99.40 0.55 0.01 0.005 99.44 0.50 0.01 0.004 79.21B 99.15 0.71 0.07 0.035 99.18 0.67 0.05 0.032 71.41C 99.48 0.27 0.12 0.006 99.50 0.24 0.08 0.006 32.7__________________________________________________________________________ Note: The electrofused magnesia clinker ingots obtained from each raw material was crushed into grains and classified into a grain size of 5 to 3 mm, 3 to 1 mm, and 1 to 0 mm. Then, the ratio by weight of single crystal of th grains of 5 to 3 mm was calculated.
In the above Table 1, samples 1A and 1B are examples of the present invention, and sample C is a comparative example. It is to be noted that samples 1A and 1B pertaining to the present invention have a higher ratio of single crystal than sample 1C for the purpose of comparison.
10 mm.times.10 mm.times.60 mm of each samples cut out of the ingots of the electrofused materials shown in Table 1, in conjunction with three additional comparative examples 1D to 1F, underwent four kinds of corrosion resistance tests. The results are shown in Table 2 below.
TABLE 2______________________________________ Corrosion resistanceChemical compo- Ratio of (melt loss index)*sition (wt. %) single Test Test Test TestSample MgO SiO.sub.2 CaO crystal (%) 1 2 3 4______________________________________1A 99.44 0.01 0.50 79.2 72 71 69 711B 99.18 0.05 0.67 71.4 76 73 74 731E 98.52 0.03 1.38 36.5 100 100 100 1001D 99.91 0.02 0.04 81.1 95 92 90 921C 99.50 0.08 0.24 32.7 97 95 96 951F 99.37 0.22 0.35 21.3 108 105 105 110______________________________________ *Note: The corrosion resistance tests were performed on samples measuring 10 .times. 10 .times. 60 mm cut out of electrofused magnesia ingots. Test 1: Dipping in molten slag having a CaO/SiO.sub.2 ratio of 1.2 at 1600.degree. C. for 15 minutes in an induction furnace. Test 2: Dipping in molten slag having a CaO/SiO.sub.2 ratio of 2.0 at 1600.degree. C. for 15 minutes in an induction furnace. Test 3: Dipping in molten slag having a CaO/SiO.sub.2 ratio of 3.0 at 1600.degree. C. for 15 minutes in an induction furnace. Test 4: Dipping in molten mill scale at 1600.degree. C. for 15 minutes in an induction furnace.
It is noted in Table 2 that samples 1A and 1B pertaining to the present invention are far superior in corrosion resistance to the comparative samples 1C to 1F. Thus the electrofused magnesia of thee present invention can be used as a filler for refractory materials of any type--shaped or unshaped, burned or unburned--to impart good corrosion resistance.
EXAMPLE 2
The chemical compositions of the electrofused magnesia clinker used in this example are shown in Table 3. Sample 2A is in accordance with the present invention, and samples 2E, 2D, 2C and 2I do not fall in the scope of the present invention.
TABLE 3______________________________________ (wt. %)Sample MgO CaO SiO.sub.2 B.sub.2 O.sub.3______________________________________2A 99.44 0.50 0.01 0.0042E 98.52 1.38 0.03 0.0322D 99.91 0.04 0.02 0.0062C 99.50 0.24 0.08 0.0062I 82.77 12.00 0.02 0.050______________________________________
Each sample of electrofused magnesia clinker shown in Table 3 was made into unburned refractory materials according to the formulation shown in Table 4, by mixing, drying at 90.degree. C. for 24 hours, and hardening at 250.degree. C. for 10 hours.
In Table 4, samples 25 and 26 were further burned at 1000.degree. C. in a reducing atmosphere.
Samples 21 and 24 contains 10 wt. % of electrofused magnesia according to the present invention. Samples 22 and 23 are examples in which mesophase carbon or diamond powder is respectively added to the formulation containing electrofused magnesia of the present invention. Samples 25 and 26 are examples of the burned products.
Refractory materials for comparison containing electrofused magnesia clinker samples 2C to 2I out of the present invention in the amount which does not fall into the scope of the present invention were prepared as shown in Table 5. These comparative examples underwent the same treatment as in the above and the properties thereof are also shown in Table 5.
Sample 26 is a comparative example in which the abovementioned unburned refractory was further burned at 1000.degree. C. in a reducing atmosphere.
Comparative samples 21, 22, 23, 24 and 25 are unburned refractories which are inferior in corrosion resistance because they contain none or insufficient amount of the electrofused magnesia pertaining to the present invention.
Comparative sample 26, which is a burned one containing none of the electrofused magnesia Pertaining to the present invention, is inferior in corrosion resistance to sample 25 in Example which contains the electrofused magnesia as specified in the present invention.
Corrosion resistance (1) to (4) shown in Tables 4 and 5 is expressed in terms of index, with that of comparative example 1 being 100. It was determined by measuring the weight which the specimen had lost after immersion in a melting bath at 1600.degree. C. for 15 minutes, heated by a high-frequency induction furnace. The content in the melting bath was slag (CaO/SiO.sub.2 =1.2) for Test 1, slag (CaO/SiO.sub.2 =2.0) for Test 2, slag (CaO/SiO.sub.2 =3.0) for Test 3, and mill scale for Test 4.
TABLE 4______________________________________Example No. 21* 22* 23* 24* 25** 26**______________________________________Composition(wt. %)Electrofused 50 50 10 86 50 10magnesia AElectrofused 24 25 24 25magnesia EElectrofused 41 42magnesia DElectrofusedmagnesia CElectrofused 24magnesia ICarbonaceouspowerNatural 20 15 15 10 20 18graphiteMesophase 5carbonDiamond 3powerMetallic 3 3 3 2 3 3aluminumOrganic 3 3 3 2 3 2binderCharacteristicpropertiesBulk density 2.84 2.84 2.85 2.89 2.78 2.78Apparent 3.8 3.7 3.7 3.6 1.5 1.8porosity (%)Compressive 421 430 441 461 320 380strength(kg/cm.sup.2)High- 128 131 139 140 130 140temperatureflexuralstrength(kg/cm.sup.2)Corrosion 93 85 80 89 93 83resistance(1) indexCorrosion 89 87 82 83 90 90resistance(2) indexCorrosion 86 87 86 81 88 80resistance(3) indexCorrosion 93 95 93 89 90 88resistance(4) index______________________________________ *Unburned **Burned
TABLE 5______________________________________Example No. 21* 22* 23* 24* 25* 26**______________________________________Composition(wt. %)Electrofused 4magnesia 2AElectrofused 70 74magnesia 2EElectrofused 74 74magnesia 2DElectrofused 74magnesia 2CElectrofused 74magnesia 2ICarbonaceouspowerNatural 20 20 20 20 20 20graphiteMesophasecarbonDiamondpowerMetallic 3 3 3 3 3 3aluminumOrganic 3 3 3 3 3 3binderCharacteristicpropertiesBulk density 2.82 2.85 2.97 2.86 2.84 2.85Apparent 3.9 4.0 3.6 3.7 3.8 1.9porosity (%)Compressive 410 420 468 438 412 395strength(kg/cm.sup.2)High- 125 120 146 132 124 140temperatureflexuralstrength(kg/cm.sup.2)Corrosion 100 98 111 121 100 99resistance(1) indexCorrosion 100 110 107 112 103 130resistanct(2) indexCorrosion 100 103 103 106 116 122resistance(3) indexCorrosion 100 99 108 136 127 102resistance(4) index______________________________________ *Unburned **Burned
Tables 4 and 5 clearly indicate that the samples of the present invention are far superior to the comparative samples in the melt loss index regardless of whether they are burned or not.
EXAMPLE 3
Specimens, measuring 10 mm.times.10 mm.times.60 mm, cut out of electrofused magnesia ingots of different composition, underwent four kinds of corrosion resistance tests and a slaking test conforming to the method of Japan Society for the Promotion of Science. The results are shown in Table 6.
TABLE 6______________________________________ SlakingChemical Corrosion resistance resistancecomposition (melt loss index)* (index)(wt. %) Test Test Test Test Increase inSample MgO CaO SiO.sub.2 1 2 3 4 weight**______________________________________3J 99.73 0.21 0.02 57 57 56 57 1083K 99.44 0.45 0.01 58 55 56 57 1323L 98.89 0.90 0.01 63 59 62 62 1473M 98.11 1.71 0.02 65 63 62 64 1493N 99.84 0.11 0.02 100 100 100 100 1003O 99.37 0.31 0.22 112 107 108 110 873P 98.52 1.38 0.05 91 90 90 91 1533Q 97.51 2.25 0.41 93 95 93 94 429______________________________________ * Specimens, measuring 10 mm .times. 10 mm .times. 60 mm, cut out of electrofused magnesia ingots underwent corrosion resistance tests. Test 1: Dipping in molten slag having a CaO/SiO.sub.2 ratio of 1.2 at 1600.degree. C. for 15 minutes in an induction furnace. Test 2: Dipping in molten slag having a CaO/SiO.sub.2 ratio of 2.0 at 1600.degree. C. for 15 minutes in an induction furnace. Test 3: Dipping in molten slag having a CaO/SiO.sub.2 ratio of 3.0 at 1600.degree. C. for 15 minutes in an induction furnace. Test 4: Dipping in molten mill scale at 1600.degree. C. for 15 minutes in an induction furnace. **The slaking resistance test was performed on grains of 3.36 to 1.00 mm in size obtained by the crushing of electrofused magnesia, followed by classification. This test conforming to the method of Japan Society for the Promotion of Science consists of heating the specimen in an autoclave at 130 to 136.degree. C. for 3 hours under 5 atms.
It is noted from Table 6 that samples 3J to 3M of the present invention are far superior to comparative samples 3N to 3Q in corrosion resistance without causing any problem in slaking resistance. These data suggest that the electrofused magnesia pertaining to the present invention can be made into refractory materials of any kind, burned or unburned, shaped or unshaped.
EXAMPLE 4
The bricks shown in Table 8 below were prepared from electrofused magnesia clinker each containing CaO and SiO.sub.2 as shown in Table 7. Samples 4R and 4S accord with the present invention, and samples 4T and 4U are magnesia clinker out of the scope of the present invention.
TABLE 7______________________________________Sample CaO SiO.sub.2______________________________________4R 1.38 0.0184S 0.21 0.0184T 0.31 0.2204U 2.12 0.018______________________________________
TABLE 8__________________________________________________________________________Example No. 41* 42* 43* 44* 45* 46** 47**__________________________________________________________________________Composition (wt. %)Electrofused magnesia 4R 50 50 50 10 10 50 50Electrofused magnesia 4S 24 24 24 24 36Electrofused magnesia 4T 2Electrofused magnesia 4U 64 15Electrofused maglime clinker 50Carbonaceous powerNatural graphite 20 15 15 20 20 20 10Mesophase carbon 5Diamond power 3Metallic aluminum 3 3 3 3 2 3 2Organic binder 3 3 3 3 3 3 2Characteristic propertiesBulk density 2.87 2.86 2.86 2.86 2.85 2.80 2.81Apparent porosity (%) 3.7 3.7 3.7 3.7 3.8 6.7 6.6Compressive strength (kg/cm.sup.2) 440 452 462 432 415 442 450High-temperature flexural strength (kg/cm.sup.2) 136 145 140 131 115 138 141Corrosion resistance (1) index 93 88 92 96 88 88 86Corrosion resistance (2) index 88 87 85 92 94 87 86Corrosion resistance (3) index 84 82 83 87 109 84 87Corrosion resistance (4) index 80 78 79 89 104 78 84__________________________________________________________________________ *Unburned **Burned (1) Dipping in molten slag having a CaO/SiO.sub.2 ratio of 1.2 at 1600.degree. C. for 15 minutes in an induction furnace. (2) Dipping in molten slag having a CaO/SiO.sub.2 ratio of 2.0 at 1600.degree. C. for 15 minutes in an induction furnace. (3) Dipping in molten slag having a CaO/SiO.sub.2 ratio of 3.0 at 1600.degree. C. for 15 minutes in an induction furnace. (4) Dipping in molten mill scale at 1600.degree. C. for 15 minutes in an induction furnace.8
Each formulation of Table 8 is selected from each electrofused magnesia clinker shown in Table 7, and basic refractory bricks are obtained by friction molding with the aid of an adequate amount of liquid phenolic binder, followed by drying at 90.degree. C. for 24 hours and hardening at 250.degree. C. for 10 hours. Samples 46 and 47 are further burned at 1000.degree. C. in a reducing atmosphere.
Samples 41 and 44 contain more than 10 wt. % of electrofused magnesia. Samples 42 and 43 contain mesophase carbon or diamond powder, respectively.
Sample 45 contains more than 10 wt. % of electrofused magnesia in an electrofused maglime clinker material. Samples 46 and 47 are burned products.
Comparative compositions containing, as raw materials, electrofused magnesia clinker samples 4T and 4U in Table 7, out of the present invention, in the amount which does not fall into the scope of the present invention were prepared as shown in Table 9. These comparative examples underwent the same treatment as in the above and the properties thereof are also shown in Table 9. Comparative sample f in Table 9 shows an example of a burned brick.
TABLE 9______________________________________Example No. a* b* c* d* e* f**______________________________________Composition(wt. %)Electrofused 4 4 50 30 4magnesia 4RElectrofused 42 23magnesia 4SElectrofused 70 20magnesia 4TElectrofused 70 74magnesia 4UElectrofused 50maglimeclinkerCarbonaceouspowerNatural 20 20 2 40 20 20graphiteMesophasecarbonDiamondpowerMetallic 3 3 3 3 2 3aluminumOrganic 3 3 2 4 3 3binderCharacteristicpropertiesBulk density 2.86 2.87 3.02 2.79 2.84 2.80Apparent 3.8 3.8 3.1 4.8 3.9 6.9porosity (%)Compressive 430 420 490 460 410 419strength(kg/cm.sup.2)High- 132 125 170 78 108 135temperatureflexuralstrength(kg/cm.sup.2)Corrosion 100 99 131 140 92 97resistance(1) indexCorrosion 100 100 123 133 99 99resistanct(2) indexCorrosion 100 109 120 125 118 100resistance(3) indexCorrosion 100 102 130 121 119 97resistance(4) index______________________________________ *Unburned **Burned Corrosion resistance: (1) Dipping in molten slag having a CaO/SiO.sub.2 ratio of 1.2 at 1600.degree. C. for 15 minutes in an induction furnace. (2) Dipping in molten slag having a CaO/SiO.sub.2 ratio of 2.0 at 1600.degree. C. for 15 minutes in an induction furnace. (3) Dipping in molten slag having a CaO/SiO.sub.2 ratio of 3.0 at 1600.degree. C. for 15 minutes in an induction furnace. (4) Dipping in molten mill scale at 1600.degree. C. for 15 minutes in an induction furnace.
It is noted that comparative samples a, b, c, d and e provide a corrosion resistance that is inferior to the samples pertaining to the present invention because they contain non or insufficient electrofused magnesia, or because they contain carbonaceous powder in an insufficient or excessive amount.
It is noted that comparative sample f, which is a burned sample not containing the electrofused magnesia pertaining to the present invention, provides a corrosion resistance that is inferior to Sample 46 containing the electrofused magnesia as specified in the present invention.
These data suggest that the refractory materials pertaining to the present invention are superior in corrosion resistance in terms of melt loss index, whether they are burned or unburned.
EXAMPLE 5
This example demonstrates the application of electrofused magnesia to castables.
TABLE 10______________________________________Sample 5A 5B 5C*______________________________________MgO (wt. %) 99.18 99.44 99.50CaO (wt. %) 0.67 0.45 0.24SiO.sub.2 (wt. %) 0.05 0.01 0.08______________________________________ *For comparison
TABLE 11______________________________________ Sample Sample ComparativeExample 51 52 Sample 51______________________________________Formulation (wt. %)Electrofused magnesia 5A5-3 mm 153-1 mm 301-0 mm 20Electrofused magnesia 5B5-3 mm 153-1 mm 301-0 mm 20Electrofused magnesia 5C5-3 mm 153-1 mm 301-0 mm 20Sintered magnesia fine powder 30 30 30Alumina cement 3 3 3Silica flour 2 2 2Dispersing agent +0.1 +0.1 +0.1Physical propertiesBulk density (%)110.degree. C. .times. 24 h 3.03 3.04 3.011500.degree. C. .times. 3 h 3.02 3.01 3.01Apparent porosity (%)110.degree. C. .times. 24 h 16.0 15.8 16.41500.degree. C. .times. 3 h 18.1 18.3 17.9Flexural strength (kg/cm.sup.2)110.degree. C. .times. 24 h 38 36 411500.degree. C. .times. 3 h 75 69 83Linear change ratio (%)1500.degree. C. .times. 3 h -0.42 - 0.35 -0.55Corrosion resistance * 89 83 100Melt loss index.______________________________________ * Evaluated by measuring corrosion by slag (CaO/SiO.sub.2 = 3.0) on the lining of a highfrequency induction furnace at 1650.degree. C. for 5 hours.
Castable refractories in Table 11 are obtained by mixing and molding the electrofused magnesia having chemical compositions as specified in Table 10. Each sample contains 5.6% of a casting ingredient. It is noted that samples 51 and 52 pertaining to the present invention are superior in corrosion resistance.
EXAMPLE 6
This example demonstrates the application of electrofused magnesia to refractory ramming materials.
Samples shown in Table 12 were prepared by formulating the samples of Table 10.
TABLE 12______________________________________ Sample Sample ComparativeExample 61 62 Sample 61______________________________________Formulation (wt. %)Electrofused magnesia 5A5-3 mm 153-1 mm 301-0 mm 24Electrofused magnesia 5B5-3 mm 153-1 mm 301-0 mm 24Electrofused magnesia 5C5-3 mm 153-1 mm 301-0 mm 24Sintered magnesia fine powder 28 28 28Bittern (32 Be) +5 +5 +5Silica flour 3 3 3Borax +0.5 +0.5 +0.5Physical propertiesBulk density (%)110.degree. C. .times. 24 h 2.98 2.99 2.961500.degree. C. .times. 3 h 2.93 2.93 2.89Apparent porosity (%)110.degree. C. .times. 24 h 14.3 14.0 14.81500.degree. C. .times. 3 h 20.0 19.8 20.1Flexural strength (kg/cm.sup.2)110.degree. C. .times. 24 h 81 71 861500.degree. C. .times. 3 h 103 92 109Linear change ratio (%)1500.degree. C. .times. 3 h -0.16 -0.13 -0.20Corrosion resistance * 84 77 100Melt loss index.______________________________________ * Evaluated by rotating corrosion test with electromagnetic steel scale a 1450.degree. C. for 30 minutes 10 cycles.
Further, the samples of electrofused magnesia shown in Table 12 were mixed by a sand mill into refractory ramming materials for a heating furnace. The sample for quality evaluation was molded under a pressure of 400 kg/cm.sup.2. It is noted from Table 12 that samples 61 and 62 pertaining to the present invention are superior in resistance to corrosion by electromagnetic steel slag.
INDUSTRIAL FEASIBILITY
(1) The electrofused magnesia of the present invention can be obtained from a magnesia raw material of comparatively low purity. It has a high ratio of single crystal as well as a high CaO/SiO.sub.2 ratio. CaO concentrated on the grain boundary reacts with slag to raise the slag viscosity, thereby preventing the infiltration of slag into the grain boundary. Because of this property, the electrofused magnesia can be used as a filler for refractory bricks to provide good corrosion resistance.
(2) The electrofused magnesia according to the present invention used as a filler improves refractory materials in terms of strength, toughness, and elastic modulus at high temperatures.
(3) The electrofused magnesia can be produced more economically with less electric power than the conventional product if the magnesia raw material is of the same purity.
(4) The electrofused magnesia gives rise to a filler composed of single crystal grains. It contains a trace amount of CaO-SiO.sub.2 in the form of a solid solution, which, during the use of the refractory bricks, separates out to wet the surface of the grains, covering the grains with a highly viscous film on account of the high CaO/SiO.sub.2 ratio. This produces the following two effects.
(a) The film of the high CaO/SiO.sub.2 ratio itself functions as a sintering agent between the grains of the basic filler. In the case of unburned bricks, this promotes sintering of the grains of the basic filler at the temperature of using, imparting to them high strength and high corrosion resistance.
(b) In the case of carbon-containing basic bricks, the highly viscous film of the high CaO/SiO.sub.2 ratio presents in the filler, which covers carbon fine particles, effectively protecting the carbonaceous powder from oxidation.
(5) For reasons mentioned above, the electrofused magnesia will find use as lining bricks, burned or unburned, for high temperature refining furnaces such as converters of high secondary combustion ratio and stainless steel melting furnaces.
(6) Owing to its high ratio of single crystal, the electrofused magnesia will find use as inexpensive optical windows, electronic device substrates, and crucibles of magnesia single crystal, in addition to ordinary refractory materials.

Number	Date	Country
3-238313	Sep 1991	JPX
3-308055	Nov 1991	JPX
4-001782	Jan 1992	JPX

Number	Name	Date
3770467	Spencer	Nov 1973
3808014	Spencer et al.	Apr 1974
4585743	Yamamoto et al.	Apr 1986

Number	Date	Country
50-96606	Jul 1975	JPX
54-8206	Apr 1979	JPX
61-111961	May 1986	JPX
63-132557	Jun 1986	JPX
61-232264	Oct 1986	JPX
1103936	Apr 1989	JPX

Refractory material and product thereof containing low-silica electrofused magnesia clinker

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