Name of the invention: spray materials
Technology areas
[0001] 　About the spraying material used in the invention, etc. of industrial kiln and furnace furnace wall mending the combustion heat of the metal powder spraying method.
His innovations.
[0002] 　There is as a furnace wall mending method of industrial kiln and furnace repair parts to sprayed refractory raw material powder spraying method. Spraying known flame spraying, plasma spraying, and laser thermal spraying. However, spraying these require either major equipment equipment is expensive and relies on complicated operations.
[0003] 　How served in the carrier gas with oxygen spray to coat 施工面 thermally sprayed refractory raw material powder and metal powders, including as the main material, on the other hand, using metal powder combustion heat refractory raw material powder liquid adhere is known. This spraying the device structure is fairly easy, and, besides, easy in operation. In addition, with plasma spraying and laser compared to spray large amounts of construction, suitable for repairing a furnace wall.
[0004] 　Thermal Spray materials containing magnesia quality powder, powder metal Si and silica quality as the spray material that is used in the burning heat of the metal powder spraying method is known (for example, on the patent documents, reference 1). In addition, thermal spraying materials include calcia quality powder, powder metal Si and silica quality is also known (for example, patent literature 2). Ensure ignition and sustained combustion ignition catalyst and combustion adjuvant, including thermal spray materials is well known (for example, patent document 3).
Prior art documents
Patent documents
[0005] Patent literature: open public no. 2006-098029 report
Patent literature 2: open 2006-151771 issue public report
Patent literature 3: special opening 2012-188345 issue public report

Summary of the invention
Inventors are trying to solve a problem
[0006] 　For example, in the patent literature 1 reactive magnesia quality flour and ingredients have created SiO2 reacted with the oxygen carrier gas metal Si powder thermal spray materials containing magnesia quality powder, powder metal Si and silica quality, as stated, and SiO2 (MgO+SiO2→ MgO, SiO2) by improves the adhesion and adhesive properties, and promote quality silica powder melting heat. Reaction to generate a SiO2 , Si powder metal reacts with oxygen in the above, with a burning fever. For this reason, may increase the heat by adding large amounts of metallic Si powder, to improve adhesion between concrete bodies and bonding. However, this spraying, equipment configuration on the limited amount of oxygen. Increase the amount of oxygen causing crashing of 施工面 this spraying, the spray refractory raw material powder and metal Si powders from exothermic reaction that increases the oxygen transfer velocity will rather increase the refractory raw material powder and metal Si powder cooling and rebound from that. Because of this, and added metal Si powder under the limited oxygen and how efficiency better combustion reaction to what will become important.
[0007] 　If the addition of large amounts of metallic Si powder combustion required oxygen becomes inadequate, does not contribute to the exothermic reaction still end up burning metal Si powder remains during construction. Could melt the silica quality powder is in the aggregate, on the other hand, the insufficient amount of metallic Si powder and MgO quality powders and degrades the adhesive strength of construction of the 施工面.
[0008] 　Also occurs by exothermic reaction of metallic Si powder and oxygen SiO2 and then in the above formula SiO2 , MgO and reacts. You need to reduce the particle size of the raw material to produce this reaction effectively, as noted in the patent literature 1 (paragraph 0024 and 0026, paragraphs), reaction from which metal Si powder and MgO quality powder.
[0009] 　But turns out that it is not enough to do an efficient reaction only inventors investigated in detail for the above reaction of metallic Si powder and MgO quality powder particle size to just a small. That is, grain size, even the smallest amount of metal Si and magnesia quality flours and balance is bad and cause problems. For example, addition of magnesia quality powder additive amount of metallic Si powder for excessive low SiO2 to generate a fever, so during the construction would remain unreacted magnesia quality powder. In addition, proper particle size distribution of metal-Si powders addition and magnesia than cause problems. For example, magnesia quality powder more magnesian quality powder particle size in magnesia quality powder particle size distribution, particle size small, large particle magnesia quality powder much included, so they remained during the construction of unreacted magnesia quality powder. Furthermore, these problems are refractory raw material powder is produced only in the case of magnesia quality powder, not patent documents 2 calcia quality flour to replace the magnesia quality powder may used as calcia quality powder, as well as problems arise.
[0010] 　Noted above as less metal Si powder combustion and unreacted magnesia quality powder or calcia quality remains during construction and construction of becomes noticeable. The reason is as follows.
[0011] 　For kiln operation is repeated on a regular basis in the kiln walls, especially in the furnace mouth coverings are exposed to repeated heating and cooling environment. Causes swelling remained under this environment, metal Si powder during the construction, by the repeated heating and cooling oxidized Si and SiO2 , due to expansion cracks may form in the body. To do so, spalling of concrete crack becomes noticeable. Magnesia quality flour (or calcia quality) as well as remaining are in construction, and magnesia quality flour (or calcia quality) is thermal expansion due to the repeated heating and cooling of the cracks may form in the body. To do so, spalling of concrete crack becomes noticeable. For this reason, patent documents 1 and 2 sprayed in spraying carried out even if the less metal Si powder combustion and unreacted magnesia quality powder or calcia quality during construction included large amounts of heating and cooling repeatedly after the construction of outstanding problems that will be.
[0012] 　Spraying spraying technique using metal powder on the heat release is also under construction continuously sprayed and sprayed ignition by metal Si powder thermal spray material during combustion at the beginning pilot or heat the furnace walls remaining, followed by overheating due to combustion of metallic Si powder is a flashpoint, are sequentially spray combustion, sprayed molten adhesive is. Therefore, spray ignition of thermally sprayed at the beginning of (hereinafter referred to as the "initial ignition performance". ) And not enough strong bonding of 施工面 refractory powders that can't.
[0013] 　Added ignition promoter iron to ensure this at patent documents 3, the initial ignition of examples listed, but the addition of iron and low fusion or another for wide swings in expansion characteristics by producing a mineral phase, after the repeated heating and cooling of (hereinafter referred to as "repeat after adhesion and. ) To decline.
[0014] 　Also, ensure by promoter ignition ignition enhancement in the patent literature 3 ignition promoter for metal powder particle size is 100 m less than listed because (paragraph 0037). But alone simply metal powder atomization to the sprayed from higher dust of challenges arise.
[0015] 　Furnace wall mending of industrial kiln and furnace for thermal spraying construction challenge trying to solve the present invention, there is as good after the repetition of 施工面 adhesion to maintain and improve the initial ignition of preventing tilework fall-off in construction, as well as, and development is to reduce dust and sprayed.
Means for resolving problems
[0016] 　Got the knowledge that inventors, is an important parameter as a result, contribute to the initial ignition of ultrafine grain size 10 µm metal-Si powder. Also improves the reactivity of thermally sprayed to keep the balance of the amount of basic compounds such as spraying material in specific grain size less metal Si and magnesia quality flours and improve adhesion by repeatedly, and improves the reactivity of thermally sprayed by ultrafine grain size 10 µm metal-Si powder is also efficiently burned, and Japan got the dust of that knowledge. Atomization, and from that contrary to common general knowledge as the dust of the grain diameter of 10 µm metal-Si powder to burn efficiently metal Si unread metal Si in fuel decreases, from dust of that knowledge gained.
[0017] 　I.e., sprayed according to the 1 view invention of oxygen or oxygen-containing gas spray in the 施工面 as the carrier gas, in metallic Si powder combustion heat melting adhere to the 施工面 of the Ca and Mg components at least one basic compounds 2% or more, 25% less than the metal on the powder 10% or more, 30% less than the silica quality powders and arminasirica quality of the powder contained in refractory powder from selection is one or two over 50% or more 86 (WT %) contains the following Wherein basic compound 100 mass percent in grain size 0. spraying 100 mass percent in grain diameter 20 µm metal-Si powder ratio is 10% or more, and 25% less than the basic compound of 15 mm or less percentage is 30% or more (percentage of the metal Si powder spray 100 mass percent in grain diameter 20 µm (mass %)) / (100 mass percent during thermal spraying materials grain size 0. the percentage of wherein the basic compound of 15 mm or less (mass %)) 0. Sprayed metal Si powder particle size 10 µm, wherein metal Si powder 100 mass percent in more than 8 and less than 10 percent by weight 60% or more are provided.
Advantageous effects of invention
[0018] 　According to the present invention, ultrafine particle size 10µm or less can improve the initial ignition by using metal-Si powder containing 60% or more.
[0019] 　Moreover, according to the present invention, metal Si powder spraying material in certain grain size following and basic compounds with the amount of adopting reasonable percentage of balanced and reasonable, and Si metals and basic compounds in particular grain diameter below metal Si powders and basic compounds, causing efficient metal Si powder combustion resulting from combustion of metallic Si powder in addition to SiO2 and basic compounds derived from MgO or CaO reaction proceeds efficiently. You can therefore, to prevent the spalling of concrete and can prevent large amounts of metallic Si powder and basic compounds remained in construction, and sprayed after heating and cooling repeatedly even after the good adhesion of 施工面 again after. In addition, that metal Si powder combustion reaction proceeds efficiently with ultrafine particle size 10µm or less using metal-Si powder containing 60% or more, even from can minimize the dust of.
[0020] 　Further, according to the present invention, ultrafine particle size 10µm or less still does not react with metal Si powder containing 60% or more, by efficiently burning metal on metal Si in fuel decreases the departure can minimize the dust of.
For carrying out the invention
[0021] 　Thermal spraying materials of the present invention, Ca and Mg components at least one basic compounds (hereinafter the basic compound. ), Comprising more than 50 mass % and 86% less than one selected from the 2% or more, 25% less than the metal on the powder contained a powder of 10% or more, 30% less than quality powder silica and alumina - silica refractory powder or two or more.
[0022] 　As a basic compound typically used magnesia quality powder or calcia quality powder. Examples of magnesia quality powder is that species are selected from magnesia powder and MgO - Cao powder, MgO-Al2O3 of spinel powder, magnesia - calcia - silica powder or two or more. Examples of calcia quality powder is that one will be selected from powder calcia, magnesia - calcia powder, Cao - silica powder or two or more. These could be any of the sintering and electro fusion products, the MgO content of magnesia quality powder by 25% or more preferably, quality powders on Cao CaO content of the 75 mass % more than is desirable. You can also use calcium hydroxide, magnesium hydroxide, calcium carbonate, magnesium carbonate, magnesium sulfate, etc. as of basic compounds.
[0023] 　Compounds use percentage to 2% or more, and 25% less than. Continuous combustion is not stable if less than 2 weight percent of 施工面 temperature is lower, and less on adhesive strength of adhesive and again after. Exceeds the 25% fewer minutes, metallic Si powder or silica quality, loss of metallic Si powder, powder silica quality characteristics. 4, the percentage coverage of basic compounds. Preferable to less than 20% and 5% or more.
[0024] 　Also, in terms of the particle size distribution of basic compounds as the grain size 0... What is the percentage of particles of less than 15 mm weight 30% or more to use. Grain size 0. the percentage of particles of less than 15 mm remains less than 30 mass % during the construction of MgO or CaO, poor adhesion after repeatedly.
[0025] 　As the metal Si powder commonly used as a refractory material that can be used. Specifically to the metal Si powder, contained 10% or more, and 25% less than grain diameter 20 µm metal-Si powder thermal spraying materials 100 mass percent during use. Grain diameter 20 µm metal-Si powder, 10 mass % less than burning heat, both poor adhesion of adhesive and again after the construction strength. Metal on the remaining during the construction of more than 25% and more, poor adhesion after repeatedly. Also the grain diameter 20 µm metal-Si powder over 25% and during the construction of metallic Si from increased dust and lead to a deterioration in the work environment.
[0026] 　Metal Si powder containing above grain diameter 20 µm diameter non-also good. To 10% or more, 30% less than the percentage of metallic Si particles in the sprayed material is. 10 mass %, above as well as inferior to the adhesive strength of adhesive and again after the construction strength. Also, if metal Si particles in the sprayed material usage exceeds % 30 mass above as well as during the construction of metallic Si powder from increased dust and lead to a deterioration in the work environment.
[0027] 　Also, in terms of particle size distribution as the metal Si powder, 60% or more by percentage of ultrafine particle size 10µm or less use. Less than 60 weight percent, unable to secure sufficient early ignition. Also still does not react in less than % 60 mass particle diameter 10 m ultra metal Si powder more because fuel metal silicon increases this still of burning metal on the floating from more dust.
[0028] 　Examples of silica quality flour to use in this invention include silica sand, natural quartz powder, fused silica powder and silica or ceramic powder with these ingredients, etc. Alumina - silica powder quality examples include pyrophyllite, chamotte, clay, confirmation jewelry, andry site, sillimanite, from kyanite and mullite.
[0029] 　Are selected from the refractory powder contained these silica quality powders and powder of alumina - silica quality of invention, or two or more level uses 50 mass % and 86% less than 100 mass percent during thermal spraying materials. Poor volume stability of concrete in less than 50 mass %, reduce the adhesion by repeatedly. Spraying a bouncing loss increases more than 86% and decreases adhesion.
[0030] 　Also, quality powder silica and alumina - silica quality powder particle size is 2 mm or less in terms of melting is preferred. Within less than 2 mm grain size range, e.g. 1. limited to less than 5 mm or 1 mm or less in liquid differ; In addition to quality powder silica and alumina - silica quality powder particle size distribution, particle size 0's. adjusting weight 0% or more, 15% less than 3 mm or less is preferable.
[0031] 　Also, sprayed the invention is "(spraying 100 mass percent in grain diameter 20 µm metal-Si powder ratio (mass %)) / (100 mass percent during thermal spraying materials grain size 0. the percentage of basic compounds of 15 mm or less (mass %)) "(hereinafter referred to as the percentage of powder. ) 0. To adjust more than 8 and less than 10. Powder ratio is 0. Grain size 0 to the rate of particle diameter 20 µm metal-Si powder at 8 under. the percentage of basic compounds less than 15 mm multi increases too, to remain during the construction of MgO or CaO, poor adhesion after repeatedly. Ratio powder in 10 Super grain size 0 to the rate of particle diameter 20 µm metal-Si powder... reaction of MgO or CaO and SiO2 and not efficient because less particles too small a proportion of basic compounds of 15 mm or less, and burning metal Si, SiO2 to respond to basic compounds (MgO or CaO). Therefore the metal Si in construction and lack of heat itself even more, repeating after adhesion even worse. In addition, powder ratio 10 Super metal Si powder many too from dust and worse. Powder ratio is 1 or 3. Preferably less than 6.
[0032] 　Sprayed this invention combines the previously mentioned do not impair the effect of the invention to the extent non-refractory powders, and other raw materials, may be used. And other raw materials as cement, slag, slag, etc.. May be combined in the range of 10% less than for example.
Implementation example [0033] 　Table 1 shows comparative example embodiments of the present invention, table 2. Table 1 and table 2 of each evaluation also show the results. In table 1 and table 2 as quality silica powder as silica, alumina - silica quality powder as chamotte, magnesia quality powder as magnesia powder, calcia quality powder as flour calcia and magnesia - calcia quality flour, magnesia - calcia powder using.
[0034] [Table 1]

[0035] [Table 2]

[0036] 　For equipment used in each example sprayed concrete, danger of burning in material tank by backfire from the tip of the nozzle and sprayed material tank inert gas, nitrogen gas is introduced. The sprayed material is cut with a tastefully on the tank bottom feeder, oxygen. Less is the amount of contamination, inert gas from the tank in which oxygen, but, no obstacle to the combustion ignition of thermally sprayed.
[0037] 　In each case, the powder feed rate 50 kg/h, the 施工面 and nozzle distance 50-70 mm have sprayed 3 kg 吹付keta to the 施工面.
[0038] 　After repeatedly as the adhesion of sprayed concrete body from 1000 ° C to 300 ° C repeated 10 times heat lifting a brick (of 施工面) and adhesion was evaluated. From this assessment that the repeatedly excellent adhesion by ◎ (Yu), ○ (good),-(OK) and x (non-) of assessed in the fourth stage. I.e., if removed by construction with brick broken ◎ (Yu), cases seen where, upon seeing bond defects in appearance and construction of ejection by a chipped from the adhesive interface in ○ (good), appearance partially off-(Yes), adhering showed remarkable in appearance if x and (non-) was.
[0039] 　The amount of metal on remained glued to the 施工面 after construction in evaluated by quantitative analysis.
[0040] 　If confirmed at ignition within five seconds from the initial ignition of began construction on the 施工面 ◎ (Yu), 5 seconds over within 10 seconds if you have verified that the ignition ○ (good), 10 seconds over within 15 seconds to ignition at if-(Yes), over 15 seconds in if you have verified that the ignition or ignition has not been confirmed if x and (non-) was.
[0041] 　From evaluation of dust is sprayed concrete when from almost no dust, visibility is good, ◎ (Yu), from, visibility is good if there is little dust ○ (good), from fine construction dust and visibility is a bit bad but if-(Yes), from dust and visibility was not bad construction, x and (non-) was.
[0042] 　And score the adhesion by repeating the initial ignition of the from each evaluation of dust all ◎ (excellent) in Si and persists during the construction of the for 10% less than ◎ (Yu), is the lowest rating in each evaluation and ○ (good), and Si construction body in 10 mass % if ○ (good), each rating lowest rating (allowed) in Si and in construction, for 10% less than-(Yes), minimum evaluation of each evaluation x (non-), Or construction in SI, 10% less than x and (non-) did.
[0043] 　Example 1-16 both sprayed in the range of the present invention, the score-(possible) was over.
[0044] 　Comparative examples 1, magnesia quality powder is often is an example and construction in remains unreacted magnesia quality powder adhesion of repeating after x and (non-) became. In addition, unreacted magnesia quality flour, no heat to to endothermic from metal Si powder. For this reason, Si amount decreases the reactivity of the metal Si powder, remaining in 10% or more.
[0045] 　Comparative example 2, magnesia quality flour are a few examples, and the inadequate reaction of SiO2 with magnesia quality powder adhesion of repetition after x and (non-) became. In addition, Si much less magnesian quality flour for the remaining construction in 10% or more.
[0046] 　Many metal Si particles in thermal spraying materials, compare example 4, many grain diameter 20 µm metal-Si powder is comparing examples 3. Neither has repeatedly after adhesive x (non-) next, and persists during construction of Si content was 10% or more. In addition, from dust and x and (non-) became.
[0047] 　Comparison example 5 is in metallic Si powders are a few examples, is repeated after adhesive x and (non-) became. In addition, bonded to the 施工面 for repeatedly after the adhesion to the body of became small. Remaining during the construction of small amounts of Si content was 10% or more.
[0048] 　The comparative example 6 grain size 0... 15 mm or less magnesian quality powder a few examples, and construction in remains unreacted magnesia quality powder adhesion of repetition after x and (non-) became. In addition, Si amount of heat absorption as a comparative example of magnesia quality flour for the remaining construction in 10% or more.
[0049] 　Comparison example 7, powder ratio is 0. In case less than 8 again after adhesion x and (non-) became. Comparison example 8 example powder ratio exceeding 10, repeating after adhesion x (non-) nearby, and persists during construction of Si content was 10% or more.
[0050] 　Comparison example 9 in a small percentage of grain size 10 µm of the metal powder 100 mass % SI metal-Si powder case, the initial ignition of x and (non-) became. Also still not respond because more grain diameter 10 m ultra metal Si powder metal Si powder fuel increases, this floating fuel metal Si powder from dust is likely to be the from dust and x and (non-) became.
[0051] 　In a small percentage of grain size 10 µm of the metal powder 100 mass % SI comparison example 10 even metal Si powder cases. Unlike comparison example 9 comparison example 9 20 µ m Super 45 µm to become mass 60% less than the ratio of grain diameter of 10 µm metal-Si powder contain less metal Si powder 8 mass % the ratio of grain diameter of 10 µm metal-Si powder becomes a mass of 60% less than the present comparative examples are all metal Si powder 20 µm m should 20 µm metal Si powder during 10 μm of metallic Si powders (30 wt %) only because it contains no. Like comparison example # 9 in this example, the first stage ignition and x (non-) nearby, and unread floating fuel Si powder from dust is likely to be the from dust and x and (non-) became.
[0052] 　Comparison example 11 is the case follow the above patent literature 3 ignition promoter containing iron and the iron to low produces the fusion of this low to fluctuate with a fusion of thermal expansion repeatedly after adhesion x and (non-) became. Also, due to the oxidation of iron Weir reddish-brown from dust may cause the departure from dust and x and (non-) became.
Of the claims
[Paragraph 1] 　With oxygen or oxygen-containing gas spray in the 施工面 as the carrier gas, in metallic Si powder combustion heat melting adhere to the 施工面 of thermal spraying materials,
　Includes selected refractory powder contained in the powder of 10% or more, 30% less than quality powder silica and alumina - silica powder 2% or more, 25% less than the metal on the basic compounds containing at least one of the CA and Mg components from one or two more than 50 mass % and 86% less than
　Wherein basic compound 100 mass percent in grain size 0. 15 mm below the basic compound percentage is 30% or more,
　Spraying 100 mass percent in grain diameter 20 µm metal-Si powder ratio is 10% or more, and 25% less than
　(Percentage of the metal Si powder spray 100 mass percent in grain diameter 20 µm (mass %)) / (100 mass percent during thermal spraying materials grain size 0. the percentage of wherein the basic compound of 15 mm or less (mass %)) 0. And, with more than 8 and less than 10
　60% or more by the percentage of total wherein metal powder 100 mass % Si particle size 10µm or less metallic Si powder thermal spray materials.
[Paragraph 2] 　4 percentage of wherein the basic compound sprayed 100 mass percent of... Claim 1 in 5% or more and less than 20%, in thermal spraying materials.
[Invoice section 3] 　(Percentage of the metal Si powder spray 100 mass percent in grain diameter 20 µm (mass %)) / (100 mass percent during thermal spraying materials grain size 0. the percentage of wherein the basic compound of 15 mm or less (mass %)) more than 3. Claim 1 in 6 or less, sprayed in.