AND ALUMINA FUSED IN ARC FURNACES AND APPLIED IN MOULDS FOR THE FUSION OF CARBON STEELS, HIGH ALLOY, LOW-ALLOY STEELS AND

ESPECIALLY MANGANESE AND PRODUCTION PROCESS

The present request of patent of invention of the title above and object of description and claim in this credit title consists of an inventive solution within the scope of the chemical industry for the production of refractory paints to be applied in the painting of males and molds of silica sand, chromite and zirconium for fusing of carbon steels, high alloy, low alloy steels, manganese and irons.

The proposed solution is provided with novelty requirement with inventive step, since it does not arise from a production process in an obvious manner or from state of the art known refractory paints, being suitable to industrial applicability, meeting the requirements of patentability, especially as a patent of invention, as provided for in Article 8° of Law 9.279.

PRINCIPLES OF THE TECHNIQUE: in order to provide veracity to the context explained in the introduction, a brief explanation about the state of the art where it will be possible for a technician who currently deals with the subject to recognize their limiting aspects, for, in later time, discuss the advantages linked to the introduction of this unheard process and obtained product claimed.

In the current refractory paints state of the art, are commonly used minerals such as olivine, zirconium, magnesite, graphite, aluminum silicate, feldspar, etc... These materials are used in pure steel applications or combined into 2 or more minerals in the same mixture.

In their production are made using alcohol as a solvent at a rate of 10-30%; thixotropic agents (2-15%); fasteners (0.5- 10%) and minerals (80% - 35) to be applied by spray, brush, washing or immersion.

These paints show good technical results, but by the fact of having much free silica oxide, they can react in some cases with manganese steels, thus creating defects in fused parts.

With this, to solve such problems, are currently used paints made of zirconium, pure or mixed silicates to fuse carbon steels, low alloy, high alloy steels and stainless steel and, in the case of manganese, paints made of olivine and magnesite are used.

In case of water based paints (10 - 35%), thixotropic agents (3-15%); fasteners (1-15%), and minerals (35-80%), its application can be done successfully in the case of zirconium and pure or mixed aluminum silicates based paints to fuse carbon steels, high alloy, low alloy steels and stainless steel.

For manganese steels, which must be made from magnesite, the main problem comes from magnesite reaction with water, causing the hardening of paint.

In the patent literature, the PI0802952-0 from 7/9/2008 is a compound for removal of paint present on plastic parts and the application process of the same, that according to its features, allows, from the use of an aluminum oxide and synthesized bauxite in the form of spherical or angular grains based compound and a specific application process, the removal of paint present in plastic parts in general. This solution consists of a compound to remove paint and not of a refractory paint.

The application of bauxite and fused alumina is known for the production of refractories for furnaces or ladles, in some cases as 100% of the refractory, and in others, they are mixed with other products.

By the fact of presenting a high content of aluminum oxide and low levels of silica oxide, high melting point (over 2000C) and besides being chemically stabilized by fusion, it made us come to the conclusion that we could use these materials in the production of refractory paints for fusing all types of steels.

The applicant, knowledgeable about the restrictive aspects of current solutions, developed a refractory paint whose new chemical composition allows its use in the fusing of any type of steel.

The proposal of the present invention brings as biggest novelty, the fact of using a single paint, either alcohol or water based, to fuse all types of steels, thus, doing away with the need to use until three paints to do the same task.

This solves the problems of products mixture that generates contaminations, giving a greater control over the application process of the paint since it is a single product.

The biggest problems faced today are the quality controls paints require.

The low refractoriness of magnesite used in manganese steels, and the fact that the same reacts with water causing its hardening. In the case of carbon steels, low alloy, high alloy and stainless steel, this paint replaces with superior performance over materials made from pure zirconium, pure aluminum silicate and even those that are made from the mixture of two products.

With this invention, we have unified a single paint for fusing all types of steels and reducing costs related to conventional paints used.

To consolidate the "WATER AND ALCOHOL BASED REFRACTORY PAINT MADE FROM THE USE OF BAUXITE AND ALUMINA FUSED IN ARC FURNACES AND APPLIED IN THE FUSING OF CARBON STEELS, HIGH ALLOY, LOW-ALLOY STEELS AND ESPECIALLY MANGANESE AND PRODUCTION PROCESS", the applicant reveals a way of elaboration of the present invention through the detailed information below.

For production and obtainment of refractory paint, object of the claim that consists of a process starting with a mixture stage preferably using sigma or cawles type mixers, where occurs the addition of solvent (alcohol or water), followed by the addition of fasteners and thixotropic agents for about 20 minutes. After this stage, takes place the addition of minerals until the next mixture stage for about 20 minutes, in order to obtain a total homogeneity of the resulting solution. The process itself consists of quick and simple mixtures steps.

The refractory paint of the present invention has a chemical composition that allows it to be used for any type of steel, being characterized by containing ingredients in the proportions revealed, where:

Example 01 : water based refractory paint Water: 10-40%

Pva resin: 1-8%

Thixotropic agent: 2-15%

Fused Alumina: 30-85%

Example 02: water based refractory paint Water: 10-40%

Pva resin: 1-8%

Thixotropic agent: 2-15%

Fused bauxite: 30-85%

Example 03: water based refractory paint

Water: 10-40%

Pva resin: 1-8%

Thixotropic agent: 2-15%

Fused Alumina: 20-50%

Fused bauxite: 20-50%

Example 04: water based refractory paint

Water: 10-40%

Pva resin: 1-8%

Thixotropic agent: 2-15%

Fused Alumina: 20-50%

Fused bauxite: 20-50%

Zirconium: 10-40%

Example 05: alcohol based refractory paint Alcohol: 10-40% Phenolic resin/pva: 1-8%

Thixotropic agent: 2-15%

Fused alumina: 30-85%

Example 06: alcohol based refractory paint

Alcohol: 10-40%

Phenolic resin/pva: 1-8%

Thixotropic agent: 2-15%

Fused alumina: 20-55%

Fused bauxite: 20-55%

Example 07: alcohol based refractory paint Alcohol: 10-40%

Phenolic resin/pva: 1-8%

Thixotropic agent: 2-15%

Fused bauxite: 20-85%

Example 08: alcohol based refractory paint Alcohol: 10-40%

Phenolic resin/pva: 1-8%

Thixotropic agent: 2-15%

Fused alumina: 20-55%

Fused bauxite: 20-55%

Zirconium: 10-45%

Example 09: alcohol based refractory paint Alcohol: 10-40%

Phenolic resin/pva: 1-8% Thixotropic agent: 2-15%

Fused alumina: 20-55%

Fused bauxite: 20-55%

Magnesite: 10-45%

Example 10: alcohol based refractory paint

Alcohol: 10-40%

Phenolic resin/pva: 1-8%

Thixotropic agent: 2-15%

Fused alumina: 20-55%

Fused bauxite: 20-55%

Aluminum silicate: 10-50%

It should be highlighted that the present invention does not have its application limited to the purposes and stages herein described. It can be used for other purposes and be produced according to other methods or techniques, however, the main scope are the formulation revealed in this document, regardless it is water or solvent based, solvent, or even solvent free.