EP3268331A1 - Matériau isolant - Google Patents

Matériau isolant

Info

Publication number
EP3268331A1
EP3268331A1 EP16762481.6A EP16762481A EP3268331A1 EP 3268331 A1 EP3268331 A1 EP 3268331A1 EP 16762481 A EP16762481 A EP 16762481A EP 3268331 A1 EP3268331 A1 EP 3268331A1
Authority
EP
European Patent Office
Prior art keywords
weight
granular material
insulating material
heat sensitive
fly
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP16762481.6A
Other languages
German (de)
English (en)
Other versions
EP3268331A4 (fr
Inventor
Maurice Lacasse
Luc Desrosiers
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Pyrotek Inc
Original Assignee
Pyrotek Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US14/643,562 external-priority patent/US9834475B2/en
Application filed by Pyrotek Inc filed Critical Pyrotek Inc
Publication of EP3268331A1 publication Critical patent/EP3268331A1/fr
Publication of EP3268331A4 publication Critical patent/EP3268331A4/fr
Withdrawn legal-status Critical Current

Links

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    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/64—Burning or sintering processes
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    • C04B33/00—Clay-wares
    • C04B33/02—Preparing or treating the raw materials individually or as batches
    • C04B33/13—Compounding ingredients
    • C04B33/131—Inorganic additives
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    • C04B33/00—Clay-wares
    • C04B33/02—Preparing or treating the raw materials individually or as batches
    • C04B33/13—Compounding ingredients
    • C04B33/132—Waste materials; Refuse ; Residues
    • C04B33/1328—Waste materials; Refuse ; Residues without additional clay
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    • C04B33/132—Waste materials; Refuse ; Residues
    • C04B33/135—Combustion residues, e.g. fly ash, incineration waste
    • C04B33/1352—Fuel ashes, e.g. fly ash
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    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P40/00—Technologies relating to the processing of minerals
    • Y02P40/60—Production of ceramic materials or ceramic elements, e.g. substitution of clay or shale by alternative raw materials, e.g. ashes

Definitions

  • WOLLITE ® An example of an insulation material presently in use is sold under the trademark WOLLITE ® .
  • This material which forms the subject matter of U.S. Pat. No. 5,360,771, the disclosure of which is herein incorporated by reference, is a solid, light weight mineral foam obtained by reaction of a woUastonite suspension containing a small quantity of calcium carbonate with a phosphoric acid solution.
  • E-ZPOURTM by RexRoto a non-free flowing vermiculite powder, has been used as an insulating material.
  • Free flowing granular insulation materials also can be used in a catalytic converter apparatus for use in an exhaust system of an internal combustion engine.
  • the converter includes: a housing, the housing including a gas inlet and a gas outlet; and at least one substrate element arranged in the housing, the at least one substrate element including catalytic material, the at least one substrate element divided into a plurality of zones, each of the zones defining a generally separate flow passage connecting the inlet and the outlet in fluid communication.
  • a granular insulation can be used to form at least one wall at least partially separating the plurality of zones.
  • a method of reducing emissions from an internal combustion engine can include providing the catalytic converter apparatus as described above and placing the inlet of the apparatus in fluid communication with an exhaust gas stream of the engine
  • a method of forming an insulating material includes the steps of a) mixing from about 65 to 85% by weight of fly-ash with from about 15 to 35% by weight of a heat sensitive binder; and b) casting the mixture obtained in step (a), and c) firing the casting to at least about 800°C.
  • a free flowing insulating material having a thermal conductivity ranging between about 0.8 and about 1.8 BTUin/ft 2 hr ° F.
  • the material comprises: a) from about 65 to 85% by weight fly-ash cenospheres, b) from about 2 to 15% by weight of a heat sensitive binder; c) from 0 to about 7% by weight of a non-wetting agent selected from the group consisting of calcium fluoride, magnesium fluoride and barium sulphate; d) from 0 to about 10% by weight of a heat expandable material selected from the group consisting of vermiculite and graphite; and e) from 0 to about 1% by weight of a dust suppressant.
  • the insulating material can have a flexural strength (CMOR) greater than about 200 psi. In some instances, the CMOR can be at least about 400 psi, or even 500 psi.
  • a granular material from about 65 to 85% by weight of fly-ash and from about 15 to 35% by weight of a heat sensitive binder is provided.
  • the insulation material can comprise about 80% by weight of a fly- ash comprising cenospheres; and about 20% by weight of the heat sensitive binder.
  • the heat sensitive binder can be boric acid or anhydrous boron oxide.
  • the granular material can have a density of from 25 to 30 lb/ft 3 .
  • the density is at least 29 lb/ft 3 '
  • the granular material can have a median particle size of approximately 50 microns and a particle size ranging from 10 to 500 microns.
  • Forming another aspect of the disclosure is a method for use with a substrate having a plurality of parallel channels extending there through.
  • the method includes the steps of filling a selected plurality of the channels with a granular material manufactured in accord with the preceding paragraphs the selected granular material being arranged to produce a wall that separates the substrate into: a first portion having a first plurality of the parallel channels extending there through; and a second portion having a second plurality of the parallel channels extending there through.
  • the granular material can be sintered to form the wall.
  • the filling step can involve pouring the granular material into a plurality of cells.
  • the granular material can be vibrated during the filling process.
  • the vibration to which the granular is subjected to during the filling step can have an amplitude of about 10 millimeters and a speed of about 3 inch per second RMS.
  • Figure 1 is a plan view of a mask used in an exemplary embodiment of the method.
  • Figure 2 is a side view of the mask of Figure 1.
  • the insulation material can be made from a mixture of "fly-ash", a heat sensitive binder, and optionally a non-wetting agent.
  • the material may also include a heat expandable material and a dust suppressant.
  • “Fly-ash” is a known coal combustion by-product produced in coal fired utilities. It is usually in the form of ceramic hollow microspheres (also called “cenospheres”), which are formed during the burning of coal. These cenospheres basically consists of silica (Si0 2 ) and alumina (A1 2 0 3 ) and include nitrogen and/or other gases within their cavities.
  • the heat sensitive binder can be any kind of binder known to have a low sintering temperature. Boric acid and anhydrous boric oxide are examples of suitable binders.
  • the optional non-wetting agent can be any kind of agent known to have this property.
  • examples of such non-wetting agent include calcium fluoride, magnesium fluoride and barium sulfate.
  • the heat expandable material that is optionally used in the composition can be vermiculite or graphite.
  • the dust suppressant that is also optionally used in the composition can be any kind of product known to have such a property.
  • a dust suppressant include kerosene, mineral oils and vegetable oils.
  • the components employed are in the form of microspheres and powders, and are mixed together and formed into the desired insulation structure or fed into the structure for which insulation is required.
  • the insulation material could be used with structures for which insulation is required such as troughs, crucibles and filter assemblies as used in the aluminum, steel, or the glass industry, or as a separation member for a catalytic converter.
  • a suitable insulation material has the composition between about 65 and 85%, for example about 80%, by weight of fly-ash comprising cenospheres, about 15 to 35%, such as 20%, by weight of binder, and has a median particle size of approximately 50 microns and a particle size ranging from 10 to 500 microns.
  • these components are mixed together and cast under vibration into a thermally conductive mold.
  • the mold is then placed in an oven to reach about 400°C.
  • the insulating material is unmolded.
  • the insulation material is hard enough to be manipulated and can be machined to any desired shape.
  • the insulating material, shaped or unshaped, is then fired from about 800 to 1000°C.
  • the material is fired above 800°C, 850°C, 900°C, or even 950°C. there is a sharp increase of properties like CMOR and the granular material becomes hydrophobic. This is particularly advantageous for molten metal application where moisture can be a safety problem.
  • CMOR flexural strength
  • CCS compressive strength
  • a composition of 80% by weight of fly ash Fillite 106 from Tolsa.USA Inc. was mixed with 20 % by weight of boric acid Optibor from U.S. Borax in a Hobart mixer until homogenisation of the mix.
  • the mix was cast into a steel mold having 5 cavities of 2" X 2" X 8" and vibrated until the material was well distributed into all the cavities.
  • the steel mold and the mix was placed into an oven to a temperature of 400°C to get first set of the material.
  • the 5 bars When cool, the 5 bars were unmolded and then placed into an oven to reach a temperature of 950°C with a rate increase of 50°C/hr and then held at 950°C for 16 hr before cool down.
  • a cube of 2" was cut out of one bar from example 1, fired at 750°C, 850°C and 950°C respectively.
  • the temperature was maintained at 25 °C and a relative humidity maintained at 75% for a period of 72 hours.
  • the insulating material may be cast to get different shapes. For example, molten metal processing equipment may be formed. It is also possible to cast into a honeycomb catalyst (acting as a mold) to insulate it as described in patent publication
  • one of the parallel faces of the substrate is placed upon a rubber seal, an aluminum mask having a slit defined there through is placed upon the opposing face such that the slit lies upon the notional wall and granular material is poured upon the mask while the mask, honeycomb substrate and seal are vibrated as a unit with a vibration having an amplitude of about 10 millimeters and a speed of about 3 inch per second RMS.
  • a suitable mask 20 is shown in Figure 1 and Figure 2 and will be seen to have a slit 22 having a narrow (0.15" thick) bottom 22A and a broad (17/32") top 22B, thereby defining an elongate funnel adapted such that granular material poured upon the mask is directed towards the interior of the notional wall.
  • This mask in the manner contemplated above provides for relatively quick filling of both 900 cpi and 400 cpi bricks; for example, conventional 4.23" high bricks can be filled in 30 seconds.
  • the granular material is heat sintered to produce a wall of insulation corresponding in size to the notional wall. It has been found that a suitable sintering regime involves elevating the temperature of the granular material to 950°C at a rate of 200°C/hour and then allowing the heated product to cool to ambient temperature at 200°C/hour.
  • the ends of the insulated wall are sealed with a material that is adapted to reduce absorption of the catalyst in any subsequent wash coating step carried out on the substrate/wall combination and that is ideally adapted to dissipate during the curing of the catalyst coating.
  • Selection of a sealant suitable for this purpose is a matter of routine for persons of ordinary skill in the art and accordingly further detail is neither provided nor described.
  • the result of the sealing step is the production of an insulated catalytic substrate as described in PCT/CA2009/001187. Such an insulated substrate can be wash coated with a catalyst in any conventional manner. Wash coating forms no part of the present invention and thus is not further described.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Inorganic Chemistry (AREA)
  • Dispersion Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • Environmental & Geological Engineering (AREA)
  • Toxicology (AREA)
  • General Engineering & Computer Science (AREA)
  • Health & Medical Sciences (AREA)
  • Filtering Materials (AREA)

Abstract

La présente invention concerne un procédé destiné à être utilisé avec un substrat ayant une pluralité de canaux parallèles qui s'étendent à travers celui-ci. Ledit procédé comprend les étapes consistant à remplir, d'un matériau granulaire, une pluralité sélectionnée desdits canaux; et à consolider le matériau granulaire au moyen de chaleur. La pluralité sélectionnée de canaux est sélectionnée afin de produire une paroi qui sépare le substrat en une première partie ayant une première pluralité de canaux parallèles qui s'étendent à travers celui-ci; et une seconde partie ayant une seconde pluralité de canaux parallèles qui s'étendent à travers celui-ci.
EP16762481.6A 2015-03-10 2016-03-10 Matériau isolant Withdrawn EP3268331A4 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US14/643,562 US9834475B2 (en) 2014-04-24 2015-03-10 Method of filling a substrate having a selected plurality of channels with a granular material
PCT/US2016/021690 WO2016145144A1 (fr) 2015-03-10 2016-03-10 Matériau isolant

Publications (2)

Publication Number Publication Date
EP3268331A1 true EP3268331A1 (fr) 2018-01-17
EP3268331A4 EP3268331A4 (fr) 2019-01-23

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EP16762481.6A Withdrawn EP3268331A4 (fr) 2015-03-10 2016-03-10 Matériau isolant

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EP (1) EP3268331A4 (fr)
WO (1) WO2016145144A1 (fr)

Family Cites Families (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1448320A (en) 1974-03-04 1976-09-02 Univ Washington Lightweight inorganic material
US4433845A (en) * 1981-09-29 1984-02-28 United Technologies Corporation Insulated honeycomb seal
US4769348A (en) * 1986-07-28 1988-09-06 Kms Fusion, Inc. Fabrication of refractory insulating materials consisting essentially of a carbon matrix containing a dispersion of SiC- or Si3 N4 -lined voids
CN1203895A (zh) 1997-06-28 1999-01-06 鞍山钢铁集团公司 粉煤灰、硼泥烧结砖及其制造方法
CN1091433C (zh) 1998-12-09 2002-09-25 鞍钢集团房产建设公司粉煤灰制品厂 粉煤灰烧结制品及其制造方法
WO2001040136A2 (fr) 1999-12-02 2001-06-07 Foseco International Limited Element de construction isolant refractaire
US7083758B2 (en) * 2003-11-28 2006-08-01 Les Produits Industriels De Haute Temperature Pyrotek Inc. Free flowing dry back-up insulating material
EP3159510A1 (fr) * 2008-08-27 2017-04-26 Vida Holdings Corp. Ltd. Catalyseur
CN102059736B (zh) * 2010-12-03 2012-10-31 伊川龙海科技实业有限公司 利用铝电解废耐火材料生产保温砖的方法

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WO2016145144A1 (fr) 2016-09-15

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