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研究生：	諾薇塔 Dewi-Cahyanti, Novita
論文名稱：	盛鋼桶燃燒合成熱間修補材料之開發 Development of Hot Repairing Materials Based on Combustion Synthesis for Ladle Refractory Linings
指導教授：	鍾賢龍 Chung, Shyan-Lung
學位類別：	碩士 Master
系所名稱：	工學院 - 化學工程學系 Department of Chemical Engineering
論文出版年：	2009
畢業學年度：	97
語文別：	英文
論文頁數：	132
外文關鍵詞：	hot repiring technique, ladle lining, SHS, combustion, refractories
相關次數：	點閱：46 下載：1
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摘要

本研究主要是探討以燃燒合成法 (SHS) 製備熔煉爐體的耐高溫修補材料。藉由實驗參數的改變，如燃料、氧化劑及添加劑等，吾人已成功的開發出以SHS技術製備氧化鐵、氧化鉻以及非氧化物系列等三種修補材料的合成方法；另一方面，吾人亦以非氧化物系統進行其應用性的探討，經由實驗的結果發現：當組成條件為 Al*/Al 莫爾比為1: 0.1，且鋁粉有經過五個小時的表面處理時，所製備的修補材料具有較佳的耐溫特性，經進一步分析其機械強度為 0.54 MPa、 rebound loss為25.01 wt%、molten steel的腐蝕速率為1.121x10-3 mm/minute而molten slag 的腐蝕速率為 41.167x10-3 mm/minute。

ABSTRACT

This project is aimed at developing hot repairing materials based on combustion synthesis for ladle side-wall refractory repairing. The formulated hot repairing materials thus, were tested via simulated experiments using a furnace to examine their suitability for practical applications. In the beginning, the SHS hot repairing materials were formulated to compose of four major constituents: fuel (i.e., the desired metal particles), oxidizer (intentionally added metal oxides or naturally available O2 in air), framework (served as structure frame) and additives (for modifying combustion or product properties).

For practical application, non-Oxide system was simulated. In advanced, this system shows better refractoriness performance by applying Aluminum surface treatment issue. Different Aluminum preheating time duration and different combination of Aluminum treated (Al*) to Aluminum non-treated (Al) mol ratio also affected on the performance of combustion product. The best composition found is using 1:0.1 of Al* to Al mol ratio and 5 hours Aluminum preheating time duration. Its combustion product showed better bonding strength, lower weight percent rebound loss of material gunned, and smaller molten steel and slag corrosion rate were also showed by that best composition, which are respectively 0.54 MPa of MOR, 25.01 wt % of rebound loss, 1.121x10-3 mm/minute of molten steel corrosion rate and 41.167x10-3 mm/minute of molten slag corrosion.

TABLE OF CONTENTS
ABSTRACT in Chinese (摘要)	iii
ABSTRACT	iv
ACKNOWLEDMENT	v
TABLE OF CONTENTS	vi
LIST OF TABLES	x
LIST OF FIGURES	xii
CHAPTER 	1	INTRODUCTION	1
CHAPTER	2	REFRACTORIES	3
1	Ladle Application of Refractories…………………………….………………	4
2	Magnesium Aluminate Spinel………………………………..……………….	8
2.1 	Structure……………………………………………….……………...	8
2.2	Physical Properties………………………………….………………...	8
2.3	Alumina-Rich Spinel……………………………….………………...	9
CHAPTER	3	VARIOUS REPAIRING TECHNIQUES	13
1	Casting Block………………………………………….……………………...	13
2	Tundish Board………………………………………….…………………….	15
3	Spraying/Gunning…………………………………….……………………....	18
CHAPTER	4	SELF-PROPAGATING HIGH-TEMPERATURE SYNTHESIS 	22
1	Thermodynamic Consideration……………………………………………....	32
2	Chemical Classes of SHS Products………………………….……………….	34
3	Practical Implementation of SHS…………………………….………………	37
3.1	SHS Powder…………………………………………………….…….	37
3.2	Ceramic Materials and Items (net-shape production)………..………	38
3.3	Tungsten-Free Hard Alloys………………………………………….	39
3.4	Cast Materials and Items…………………………………………….	40
CHAPTER	5	RESEARCH PRINCIPALS AND CONSTRAIN INFORMATIONS	42
1	Research Policy, Methods and Steps…………………………………………	42
1.1	Background Infromations……………………………………………	42
1.2	Requirements to the SHS Hot Repairing Materials………………….	42
1.2.1 	Self Ignition………………………………………………..	42
1.2.2 	Self Densification and Strong Bonding with the Linings….	43
1.2.3	Properties Requirements……………………………………	43
2	Research Planning……………………………………………………………	44
2.1	Formulation of the SHS Hot Repairing Materials and Study on Their SHS Reaction Phenomena……………………………………………	44
2.1.1 	Basic Components of the Hot Repairing Materials………...	44
2.1.2	Important Problems to be Studied………………………….	45
2.2	Study on the Performance of the Formulated Hot Repairing Materials Via Simulated Experiments………………………………..	45
CHAPTER	6	EXPERIMENTAL SECTION	47
1	Materials……………………………………………………………………...	47
1.1	Iron Oxide System……………………………………………………	47
1.2	Chrome Oxide System……………………...………………………..	48
1.3	Non-Oxide System…………………………………………………...	48
2	Experimental Procedure……………………………………………………...	48
2.1	Preliminary Porosity/Densification, Ignition and Combustion Measurement…………………………………………………………	48
2.2	Surface Treatment……………………………………………………	52
3	Characterization……………………………………………………………………	55
3.1	Ignition and Combustion Temperature Measurement……………….	55
3.2	Physical Properties…………………………………………………...	57
3.2.1	Porosity…………………………………………………….	57
3.2.2	Bonding Strength…………………………………………..	58
3.2.3	Rebound Loss………………………………………………	61
3.2.4	Molten Steel and Slag Resistance………………………….	63
3.3	Chemical Properties………………………………………………….	63
3.3.1	X-Ray Diffraction…………………...……………………..	64
3.4	Microstructure………………………………………………………..	64
3.4.1	Scanning Electron Microscope…………...………………..	64
CHAPTER	7	RESULT AND DISCUSSION	66
1	Formulation of the SHS Hot Repairing Materials for Ladle…………………	66
2	Ignition and Combustion Temperature Measurements………………………	67
2.1	Iron Oxide System……………………………………………………	67
2.1.1	Ignition and Combustion Temperature…………………….	67
2.1.2	Effect of Mg Content……………………………………….	74
2.1.3	Effect of Framework Content………………………………	74
2.2	Chromium Oxide System…………………………………………….	74
2.2.1	Ignition and Combustion Temperature……………………..	74
2.2.2	Effect of Fuel Content……………………………………...	75
2.3	Non-Oxide System…………………………………………………...	79
2.3.1	Ignition and Combustion Temperature…………………….	79
2.3.2	Effect of Framework Content on Ignition Temperature……	79
2.3.3	Effect of Framework on Maximum Combustion 	Temperature………………………………………………...	79
3	Porosity Measurement……………………………………………………….	81
4	Microstructure Observation………………………………………………….	81
5	Preliminary Surface Treatment………………………………………………	85
5.1	Surface Treatment Issue……………………………………………...	85
5.2	Effect of Different Slurry Water Content…………………………….	87
5.3	Effect of Different Binder System……………………………………	93
6	Surface Treatment……………………………………………………………	98
6.1	Al Preheating Treatment……………………………………………..	98
6.2	Al2O3 Addition………………………………………………………	103
6.2.1	Effect of Different Al2O3 Amount Added………………….	103
6.2.2	Effect of Different Preheating Time………………………..	104
6.3	Combination of Al Treated (Al*) and Al non-Treated (Al)………….	110
6.3.1	Effect of Different Preheating Time………………………..	110
6.3.2	Effect of Different Al Treated (Al*) to Al non-Treated (Al) Ratio………………………………………………………...	111
6.4	Microstructure Observation…………………………………………..	115
6.5	Rebound Loss Analysis………………………………………………	121
6.6	Molten Steel and Molten Slag Analysis……………………………...	122
CHAPTER	8	CONCLUSIONS	126
REFERENCES				128
                                    

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校內：2012-07-06公開
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