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- 2019 (2) (remove)
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- Aluminiumorthophosphat (1)
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- Institut für Integrierte Naturwissenschaften, Abt. Chemie (2) (remove)
Refractory dry-vibratable mixes, which consist of a mineral filling material and an organic or anorganic binder system, are widely used for linings in industrial aggregates, where a very high temperature resistance is required (e.g. steel industry). During lining, all compounds are mixed and hardening is chemically or thermally initiated. The time span required for hardening is of special relevance for the application of refractory dry-vibratable mixes. It should be long enough for adequate processability, but simultaneously avoid too long downtimes. Prediction or regulation of the hardening time, necessary for an ideal processing, is currently limited. One the one hand, this is a result of the lack of an appropriate method for time-dependent determination of the harding process. On the other hand, the mechanisms responsible for this very complex process have not yet been investigated in detail and the effect of influencing factors, like the temperature or the composition of the refractory dry-vibratable mixes, are poorly documented.
To make a contribution to the understanding of the hardening mechanism of refractory dry-vibratable mixes, it was the aim of the present work, to develop an appropriate test method for the time-dependent investigation of this process. This was realized by means of the dynamic-mechanical analysis. In addition, the hardening mechanism was described for a refractory dry-vibratable mix with a binder system, which consists of a waterglass and a phosphate hardener (AlPO4 und BPO4), using supplement gravimetric investigations and determining solubility behavior of the phosphates. By means of X-ray diffraction analysis, nuclear magnetic resonance spectroscopy and scanning electron microscopy, the impact of the hardening mechanism on the crystal and amorphous structure was studied. It could be shown, that according to the two phosphates, the hardening leads to different network structures in respect of their link denseness. These structure characteristics correlate with the speed of the hardening reactions. In addition, the impact on selected properties (thermal linear deformation, temperature-dependent phase development and phase transition) could be deducted.
In the present dissertation, the structural interaction between potassium waterglass and aluminium metaphosphates (aluminium tetrametaphosphate and aluminium hexametaphosphate) were investigated in terms of the resettlement behaviour of the metaphosphates as hardening agents. The crystalline phase composition was described qualitatively and quantitatively in terms of powder diffraction patterns combined with Rietveld refinement. The amorphous phase content was determined by different spectroscopic methods (e.g. solid-state NMR, ATR-IR, and Raman spectroscopy). The solubility behaviour of the chemical hardening agents was investigated by optical emission spectroscopy and electron absorption spectroscopy. The mechanical properties of the samples were measured by three-point bending tests, resonance damping frequency analysis, and acid test. The structural framework of the chemically hardened waterglasses was explored by scanning electron microscopy method. It could be proven, that the reaction mechanism of the resettlement is strongly dependent on the structure of the aluminium metaphosphate. After the dissolution of the aluminium ions of aluminium tetrametaphosphate through the alkalic environment of the potassium waterglass, a potassium tetrametaphosphate is developed through an ion-exchange reaction with the waterglass` potassium ions. In the hexametaphosphate system, no analogous structure could be proven. Parallel to the ion-exchange reaction an incremental depolymerization of the cyclic metaphosphate structure to the final crystalline product potassium dihydrogen phosphate occurs. The drop in pH value due to the addition of the respective aluminium metaphosphate initiates a polycondensation of the potassium waterglass due to the decreasing stabilization of the waterglass. This process is increased by the depolymerization products of the metaphosphate, that remove further quantities of the alkali ions, which accelerates the polycondensation reaction due to a further decrease in pH value. The dissolved aluminium ions from the aluminium metaphosphate penetrate into the amorphous, hardening silica network and develops an alumosilicate binder matrix. Furthermore, amorphous hydrated aluminium phosphate phases develop in separate domains beside silicate, alumosilicate phases, and the crystalline phase contents e.g. potassium dihydrogenphosphate and the incomplete reacted aluminium metaphosphate. Consequently, the chemically hardened potassium waterglass binder is not necessarily homogenous. Regarding the mechanical and chemical properties, in summary with increasing alkali modulus the mechanical flexural strength, and the young modulus drop, while the chemical resistance towards acid attack, and the porosity of the samples increase. The change in the cyclic structure from aluminium tetrametaphosphate to aluminium hexametaphosphate leads to a drop in the acid resistance, the porosity of the samples, the flexural strength, and the young modulus.