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GB2353996A - Making fibres containing strontium oxide - Google Patents

Making fibres containing strontium oxide Download PDF

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Publication number
GB2353996A
GB2353996A GB9922834A GB9922834A GB2353996A GB 2353996 A GB2353996 A GB 2353996A GB 9922834 A GB9922834 A GB 9922834A GB 9922834 A GB9922834 A GB 9922834A GB 2353996 A GB2353996 A GB 2353996A
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GB
United Kingdom
Prior art keywords
fibres
volatile component
fibre
strontium
sro
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.)
Granted
Application number
GB9922834A
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GB2353996B (en
GB9922834D0 (en
Inventor
Gary Anthony Jubb
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.)
Morgan Advanced Materials PLC
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Morgan Crucible Co PLC
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
Application filed by Morgan Crucible Co PLC filed Critical Morgan Crucible Co PLC
Priority to GB9922834A priority Critical patent/GB2353996B/en
Publication of GB9922834D0 publication Critical patent/GB9922834D0/en
Priority to AU73017/00A priority patent/AU7301700A/en
Priority to PCT/GB2000/003590 priority patent/WO2001023315A1/en
Publication of GB2353996A publication Critical patent/GB2353996A/en
Application granted granted Critical
Publication of GB2353996B publication Critical patent/GB2353996B/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

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Classifications

    • CCHEMISTRY; METALLURGY
    • C03GLASS; MINERAL OR SLAG WOOL
    • C03CCHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C13/00Fibre or filament compositions

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  • Chemical & Material Sciences (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Geochemistry & Mineralogy (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Inorganic Fibers (AREA)

Abstract

A method of making fibres comprising SrO, Al<SB>2</SB>O<SB>3</SB>, and a fibre-forming additive (eg SiO<SB>2</SB>) comprises (a) mixing (i) a compound of strontium which loses a volatile component upon heating, (eg SrCO<SB>3</SB>), (ii) Al<SB>2</SB>O<SB>3</SB> and (iii) fibre forming additive, (b) either calcining the mixture to remove the volatile component or forming granules (c) either melting the calcined mixture or melting the granules and removing the volatile component and (d) forming fibres from the melt. The fibres may comprise 41.2-63.8 wt% SrO, 29.9-53.1wt% Al<SB>2</SB>O<SB>3</SB> and the balance SiO<SB>2</SB> apart from up to 3% impurities.

Description

2353996 METHODS OF MAKING-TNORGANIC FIBUS This invention relates to
methods ol"making man-made inorganic oxide fibres containing strontium oxide. The invention also relates to products formed by such methods.
Inorganic fibrous materials are well known and widely used for many purposes (e.g. as thermal or acoustic insulation in bulk, mat, or blanket form, as vacuum formed shapes, as vacuum formed boards and papers, and as ropes, yams or textiles; as a reinforcing fibre for building materials; as a constituent of brake lo blocks for vehicles). In most of these applications the properties for which inorganic fibrous materials are used require resistance to heat, and often resistance to aggressive chemical enviromnents.
Inorganic fibrous materials can be either glassy or crystalline. Asbestos is an inorganic fibrous material one form of which has been strongly implicated in respiratory disease.
It is still not clear what the causative mechanism is that relates some asbestos with disease but some researchers believe that the mechanism is mechanical and size related. Asbestos of a critical size can pierce cells in the body and so, through long and repeated cell injury, have a bad effect on health. Whether this mechanism is true or not regulatory agencies have indicated a desire to categorise any inorganic fibre product that has a respiratory fraction as hazardous, regardless of whether there is any evidence to support such categorisation. Unfortunately for many of the applications for which inorganic fibres are used, there are no realistic substitutes.
Accordingly there is a demand for inorganic fibres that will pose as little risk as possible (if any) and for which there are objective grounds to believe them safe.
One line of study has proposed that if inorganic fibres were made that were sufficiently soluble in physiological fluids that their residence time in the human body was short; then damage would not occur or at least be minimised. As the risk of asbestos linked disease appears to depend very much on the length of exposure this idea appears reasonable. Asbestos is extremely insoluble.
As intercellular fluid is saline in nature the importance of fibre solubility in saline solution has long been recognised. If fibres are soluble in physiological saline solution then, provided the dissolved components are not toxic, the fibres should be safer than fibres that are not so soluble. The shorter the time a fibre is resident io in the body the less damage it can do.
Such fibres are exemplified by the applicant's earlier International Patent Applications W093/15028 and W094/15883, which disclose saline soluble fibres usable at temperatures of 1000T and 1260T respectively. Fibres of these types are on sale under the trade mark SUPERWOOLTM.
Refractory fibres generally are formed by the steps of: - a) melting the constituents in a crucible to form a melt; b) allowing a stream of melt to leave the crucible, and; c) disrupting the melt stream to form fibres.
The disruption can be by many methods but typically ajet of air is used (blowing) or the stream impinges on spinning discs (spinning) although other methods such as centrifugal formation of fibres have been proposed.
In W096/04214 the applicants revealed that whereas strontium aluminate compositions do not appear to form fibres when formed from a melt, such compositions including additives such as silica do form fibres when blown from a melt. Such fibres appear to hydrate in the manner of calcium aluminate fibres and additionally show the potential for high temperature use. The content of this application in its entirety is incorporated herein by reference.
2 However such fibres, although readily formable, have processing problems when made in large quantities. Strontium oxide is a strongly alkaline and irritant material. Handling strontium oxide in large quantities can therefore be hazardous to workers. Accordingly the applicants looked to other materials as a source of s strontium that might pose fewer risks in handling.
Strontium is found chiefly as the minerals celestite (SrSO4) and strontianite (SrC03)- Use of a sulphate such as SrS04would be hazardous since on melting copious amounts of sulphur dioxide would be produced which would be hazardous and corrosive and would require complex and expensive extraction io apparatus. Much strontium carbonate is made by converting the sulphate to the carbonate but even this contains sufficient residual sulphate to poseA pollution problem when forming the melt. Additionally use of either a sulphate such as SrS04or a carbonate such as SrCO3 poses processing problems in that evolution of gases on melting can be so vigorous as to eject raw material from the melting crucible. In the glass- making industries problems with excessive outgassing are generally solved by pre-melting cutlet and dissolving the gas-generating materials in the melt so formed. However this is not practicable for strontium aluminate refractory fibres because of the need to provide a composition having low amounts of impurities; because of the high temperatures required in melting the ingredients; and because the amount of gas-generating material is high in comparison with glass making compositions. Accordingly the present invention provides a method of forming fibres comprising SrO, A1203, and a fibre-fonning additive, the method comprising the steps of.a) mixing:- i) a compound of strontium which on heating loses a volatile component 3 ii) A1203, and iii) a fibre forming additive b) calcining the mixture io remove the volatile component c) melting the calcined mixture d) disrupting the melt to form fibres.
Alternatively, the present invention provides a method of forming fibres comprising SrO, A1203, and a fibre-forming additive, the method comprising the steps of.- a) mixing:
i) a compound of strontium which on heating loses a predominantly non-toxic volatile component ii) A1203, and iii) a fibre forming additive b) forming granules from the mixture of a sufficient size to resist ejection from the melt by outgassing c) melting the granules and extracting the predominantly non-toxic volatile component d) disrupting the melt to form fibres The first alternative has the advantages that:- a) no additional gas extraction is required at the melting step, evolution of gas taking place primarily or entirely on calcining b) a stable non-irritant intermediate (in the form of the calcined mixture) is produced which is easy to handle and/or transport c) it does not involve significant outgassing at the melting stage d) extraction of gas takes place at the calcining stage where it is easier to provide than at the melting stage but has the disadvantage that an additional processing step is required.
4 The second alternative has the advantages that:- a) a stable non-irritant intermediate (in the forrn of the granulated mixture) is produced which is easy to handle and/or transport b) although there is significant outgassing at the melting stage the granulated 5 product is sufficiently heavy to resist ejection from the melt c) the granules provide a continuous path between granules by which the gas can escape without causing explosive eruptions in the batch above the melt.
but has the disadvantage that an additional processing step is required and gas extraction is required at the melting step. If no localised extraction is present then lo the amount of toxic volatile components in the predominantly -non- toxic volatile component must be kept low to minimise worker exposure. For example, if no extraction is provided and SrC03 is used as the strontium compound it must have a low S03 content, e.g. of < 0.1%, preferably < 0.05%.
For both alternatives, the A1203 and/or the fibre forming additive or part thereof may be in the form of compounds with a volatile component that is lost on melting. Advantageously the strontium is in the form of a carbonate. The invention extends to the intermediate granulated and calcined products and to the products of the methods.
The scope of the invention is made clear in the appended claims with reference to the following description and the drawing Fig. 1, which is a gTaph of compositions comprising SrO, A1203 and Si02-
The compositions plotted in Fig. I include those described in W096/04214. Such compositions may contain impurities and these should amount to less than 10%, preferably to less than 5%, of the composition so that the compositions comprise more than 90%, preferably more than 95% SrO-AI203SiO2. Advantageously the compositions contain less than 3wt %, more advantageously'less than 2wt% and still more advantageously less than lwt% incidental impurities. The compositions were tested for shrinkage and the results, normalised to 100% SrO-AI203-SiO2, are plotted on the three co-ordinate graph of Fig. 1. Contours are drawn around the compositions tested as having shrinkage of less than 3.5% at 1260'C, 1300'C, lo 1400Cjl 1450'C, 1500C, and 1550T respectively.
When made on a laboratory scale manufacture was easy. However when made in pre-production test quantities of 251-,g or more evolution Of S03 originating from the traces present in the strontium carbonate supplied would have led to rapid departure of workers from the laboratory were it not for god extraction facilities in the laboratory. Additionally evolution of carbon dioxide from the strontium carbonate led to rapid and explosive departure of powder from the melting chamber.
Provision of high capacity gas extraction in a commercial fibre forming plant would add considerably to the cost and complexity of the plant. Loss of powder from the melting chamber would not only create a mess in a commercial fibre forming plant it would also make it difficult to form fibres of a consistent quality.
When strontium carbonate,, alumina, and silica were granulated or calcined as mentioned above the problem of explosive evolution of gas was solved. Calcining also solved the problem Of S03 evolution.
6 A preferred range of compositions specified in W096/04214 was that the fibres comprise at least 90%, preferably at least 95%, by weight SrO, A1203, and a fibre forming additive, and had a composition comprising:
SrO 41.2wt% - 63.8wt% A1203 29.9wt% - 53. 1 wtO/o.
The applicant's currently preferred range is that formed by the > 1400T contour of Fig. I and in particular the composition:
SrO 58 + 0.5 wt% A1203 30 0.5 wtO/o Si02 12 0.5 wt% incidental impurities < 3wt%, preferably less than 2wtO/o, more preferably less than IwtO/o.
which shows a good compromise between formability (the Si02 giving ease of manufacture) and high temperature performance.
7

Claims (16)

1. A method of forming fibres comprising SrO, A1203, and a fibre forming additive, the method comprising the steps of-.- a) mixing:
i) a compound of strontium which on heating loses a volatile component ii) A1203, and iii) a fibre forming additive b) calcining the mixture to remove the volatile component c) melting the calcined mixture d) disrupting the melt to form fibres.
2. A method of forming fibres comprising SrO, A1203, and a fibre forming additive, the method comprising the steps of.- a) mixing:- i) a compound of strontium which on heating loses a predominantly non-toxic volatile component ii) A1203, and iii) a fibre forming additive b) forming granules from the mixture of a sufficient size to resist ejection from a melt by outgassing c) melting the granules and extracting the predominantly non-toxic volatile component d) disrupting the melt to form fibres,
3. A method according to I or claim 2 in which the A1203and/or the fibre forming additive or part thereof is in the form of compounds with a volatile component that is lost on melting.
4. A method according to any preceding claim in which the strontium is in the form of a carbonate.
5. A method of producing a calcined mixture for use in the method of claim 1, comprising the steps of.
a) mixing:- i) a compound of strontium which on heating loses a volatile component ii) A1203, and iii) a fibre forming additive b) calcining the mixture to remove the volatile component.
6. A method of producing granules for use in the method of claim 2, comprising the steps of.- a) mixing:- i) a compound of strontium which on heating loses a predominantly rion-toxic volatile component ii) A1203, and iii) a fibre forming additive b) forming granules from the mixture of a sufficient size to resist ejection from a melt by outgassing, 9
7. The method of claim 5 or claim 6 in which the A1203and/or the fibre forming additive or part thereof is in the form of compounds with a volatile component that is lost on mefting,
8. The method of any of claims 5 to 7 in which the strontium is in the form of a carbonate.
9. The method of any preceding claim in which the fibre is needled to form blanket.
10. The method of any preceding claim in which the fibres comprise at least 90% by weight SrO, A1203,and a fibre forming additive, and have a composition comprising:
Sro 41.2wtO/o - 63.8wt% 15, A1203 29.9wt% - 53. 1 wto/o 10. The method of any preceding claim in which the fibres comprise at least 90% by weight SrO, A1203,andSiO2and have a composition falling within the 1400'C contour of Fig. 1.
11. The method of claim 10 iniAich the fibres fall within the 1450T contour of Fig. 1.
12. The method of claim I I in which the fibres fall within the 1500T contour 25 of Fig. 1.
13. The method of claim 12 in which the fibres fall within the 1550T contour of Fig. 1.
14. The method of claim 10 in which the fibre has the composition:- SrO 58 0.5 wt% A1203 30 0.5 wt% Si02 12 0.5 wVlo with incidental impurities amounting to less than 3wtO/o.
15. The method of claim 14 in which incidental impurities amount to less than 2wt%.
lo 16. The method of claim 15 in which incidental impurities amount to less than lwt%.
11 Amendments to the claims have been filed as follows 1. A method of forming fibres comprising SrO, A1203, and a fibre forming additive, the method comprising the steps of-.- a) mixing:
i) a compound of strontium which on heating loses a volatile component ii) A1203, and iii) a fibre forming additive b) calcining the mixture to remove the volatile component c) melting the calcined mixture d) disrupting the melt to form fibres.
2. A method of forming fibres comprising SrO, A1203, and a fibre fom-fing additive, the method comprising the steps of.
a) mixing:
i) a compound of strontium which on heating loses a predominantly non-toxic volatile component ii) A1203, and iii) a fibre forming additive b) forming granules from the mixture of a sufficient size to resist ejection from a melt by outgassing c) melting the granules and extracting the predominantly non-toxic volatile component d) disnipting the melt to form fibres I i '2- I 3. A method according to I or claim 2 in which the A1203 and/or the fibre forming additive or part thereof is in the form of compounds with a volatile component that is lost on melting. 5 4. A method according to any preceding claim in which the compound of strontium is a carbonate. 5. A method of producing granules for use in the method of claim 2, comprising the steps of 10 a) mixing:- i) a compound of strontium which on heating loses a predominantly non- toxic volatile component ii) A1203, and iii) a fibre forming additive b) forming granules from the mixture of a sufficient size to resist ejection from a melt by outgassing 13 I 6. The method of claim 5 in which the A1203and/or the fibre forming additive or part thereof is in the form of compounds with a volatile component that is lost on melting 7. The method of any of claims 5 to 6 in which the compound of strontium is a carbonate.
8. The method of any preceding claim in which the fibre is needled to form blanket.
9. The method of any preceding claim in which the fibres comprise at least 90% by weight SrO,, A1203, and a fibre forming additive, and have a composition comprising:
Sro 41.2wt% - 63.8wt% A1203 29.9wtO/o - 53. 1 wt% 10. The method of any preceding claim in which the fibres comprise at least 90% by weight SrO, A1203, and S102and have a composition falling within the 1400C contour of Fig. 1.
11. The method of claim 10 in which the fibres fall within the 1450'C contour of Fig. I.
12. The method of claim I I in which the fibres fall within the 1500'C contour of Fig. 1.
13. The method of claim 12 in which the fibres fall within the 1550'C contour of Fig. 1.
14. The method of claim 9 in which the fibre has the composition:- Sro 58 0.5 we/o A1203 30 0.5 wt% Si02 12 0.5 wt% with incidental impurities amounting to less than 3wtO/o.
io 15. The method of claim 14 in which incidental impurities amount to less than 2wt%.
16. The method of claim 15 in which incidental impurities amount to less than Iwt%.
GB9922834A 1999-09-27 1999-09-27 Methods of making inorganic fibres Expired - Fee Related GB2353996B (en)

Priority Applications (3)

Application Number Priority Date Filing Date Title
GB9922834A GB2353996B (en) 1999-09-27 1999-09-27 Methods of making inorganic fibres
AU73017/00A AU7301700A (en) 1999-09-27 2000-09-19 Methods of making inorganic fibres
PCT/GB2000/003590 WO2001023315A1 (en) 1999-09-27 2000-09-19 Methods of making inorganic fibres

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB9922834A GB2353996B (en) 1999-09-27 1999-09-27 Methods of making inorganic fibres

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GB9922834D0 GB9922834D0 (en) 1999-11-24
GB2353996A true GB2353996A (en) 2001-03-14
GB2353996B GB2353996B (en) 2001-07-25

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Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB393896A (en) * 1932-01-22 1933-06-15 Coframet Sa Process of manufacturing aluminium and barium or strontium compounds
GB997600A (en) * 1962-02-08 1965-07-07 Patent Treuhand Ges Fuer Elektrische Gluehlampen Mbh Synthetic phosphor and method of producing it

Family Cites Families (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DK302076A (en) * 1976-07-02 1978-01-03 Rockwool Int PROCEDURE FOR THE PRODUCTION OF PRODUCTS FROM A MINERAL WOOL MELT
DE69331376T2 (en) 1992-01-17 2002-07-11 The Morgan Crucible Co. Plc., Windsor USE OF INORGANIC FIBERS, SOLUBLE IN A SALT SOLUTION, AS INSULATING MATERIAL
DE4229901C2 (en) * 1992-09-08 2003-02-27 Solvay Barium Strontium Gmbh Production of granulated strontium carbonate with binder containing strontium
WO1994015883A1 (en) 1993-01-15 1994-07-21 The Morgan Crucible Company Plc Saline soluble inorganic fibres
GB9414154D0 (en) * 1994-07-13 1994-08-31 Morgan Crucible Co Saline soluble inorganic fibres
GB9508683D0 (en) 1994-08-02 1995-06-14 Morgan Crucible Co Inorganic fibres
JP3173336B2 (en) * 1995-07-12 2001-06-04 日東紡績株式会社 High strength rock wool and method for producing the same

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB393896A (en) * 1932-01-22 1933-06-15 Coframet Sa Process of manufacturing aluminium and barium or strontium compounds
GB997600A (en) * 1962-02-08 1965-07-07 Patent Treuhand Ges Fuer Elektrische Gluehlampen Mbh Synthetic phosphor and method of producing it

Also Published As

Publication number Publication date
WO2001023315A1 (en) 2001-04-05
AU7301700A (en) 2001-04-30
GB2353996B (en) 2001-07-25
GB9922834D0 (en) 1999-11-24

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Effective date: 20040927