CA1129441A - Aluminous refractory composition containing carbon, silicon and chrome oxide - Google Patents

Aluminous refractory composition containing carbon, silicon and chrome oxide

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Publication number
CA1129441A
CA1129441A CA343,153A CA343153A CA1129441A CA 1129441 A CA1129441 A CA 1129441A CA 343153 A CA343153 A CA 343153A CA 1129441 A CA1129441 A CA 1129441A
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CA
Canada
Prior art keywords
composition
carbon
alumina
present
refractory
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.)
Expired
Application number
CA343,153A
Other languages
French (fr)
Inventor
Harold L. Rechter
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.)
Chicago Fire Brick Co
Original Assignee
Chicago Fire Brick Co
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 US06/017,270 external-priority patent/US4210454A/en
Priority claimed from US06/088,549 external-priority patent/US4233079A/en
Application filed by Chicago Fire Brick Co filed Critical Chicago Fire Brick Co
Application granted granted Critical
Publication of CA1129441A publication Critical patent/CA1129441A/en
Expired legal-status Critical Current

Links

Abstract

ALUMINOUS REFRACTORY COMPOSITIONS CONTAINING
CARBON, SILICON AND CHROME OXIDE
ABSTRACT OF THE DISCLOSURE
A composition blending carbon with powdered chro-mium oxide in an alumina or aluminum silicate matrix, includ-ing silicon metal powder to inhibit carbon oxidation, is more advantageous in resisting molten iron and slags than refrac-tories based on carbon or chrome additions not combined. The resultant refractory mixes are suitable for all conventional application methods.

Description

112~

BACKGROUND OF THE INVENTION

1. Field of the invention.
Thc invention relates to an improvement in alumin-ous refractory compositions containing carbon and silicon, the tcrm carboll including ~morphous carbon and graphite.
2. Description of the Prior Art.
The excellent ability of aluminous r~fractories containinO carbon to withstand erosion by molten iron and slag is well Icnown and such materials arc con~lonly used to advantage in iron-ulakin~ oundry and blast furnace facilities, particularly in tap hol.e and iron and slag spou.t ar~as.

The usual. carbon refractory materials exhibit tlle disadvantage of rapid o~idation at temperatures above 900 F
limiting theLr working life. Patents 3,810,768; 3,8;~6,14i~;
3,842,760 and 3,923,531, in which applicant is one of the in-ventors, disclose the combination of powdered silicon me~aLwith carbon along with aluminous refrac~ory material to in-hibit G~idation and improve mechanical properti.es. Tbese carbon refractories also exhibit slag resistance, but their slag resistance is limited by the fact that increasing the carbon content increases oxidation so that there is a prac-tical limit to t'ne amount of carbon that may be used in the composition, generally less than 50% and usually not sub-stantially higher than 35% by weight.

High alumina-chromic oxide compositions are dis-closed in Manigault U.S. Patents 3,888,687 and 3,948,670.
These compositions do not contain carbon in the form of graphite or otherwise. There is no disclosure of the value 10 of chromic oxide in increasing slag resistance and it is believed that such compositions without carbon are relatively ineffective in improving resistance against contact with basic slag compounds.

It is an object of my invention to obtain improved slag resistance without excessige high carbon content in aluminous-carbon refractory compositions.

SUMMAR~ OF THE INVENTION

I have found that the addition of chromic oxide to an aluminous refractory composition containing carbon and 20 silicon is more advantageous in resisting molten iron and slags, especially basic slags, than refractories based on carbon or chrome additions not combined. The improvement is essentially in having the chromic oxide and carbon present in the aluminous composition in amount to give greater resistance to slag over that of aluminous compositions in which the chromic oxide and carbon are absent. The improvement is es-pecially important in compositions containing up to about 35%
carbon.

The composition may contain as low as 10% of alumina or aluminum silicate, but preferably an alumina or clay aggre-gate is used containing a minimum of 40% alumina or aluminum silicate. A~ounts of alumina or aluminum silicate up to 75%
and even higher may be used depending upon the amount of carbon, chrome oxide, silicon metal and other ingredients present.

The chrome oxide may be present in 5-30% by weight, the carbon in 5-35% and the silicon metal in 5-25% or in amount sufficient to substantially inhibit oxidation of the carbon.

Compositions containing more than 35% by weight of carbon are of good slag resistance without the addition of chromic oxide although some slight improvement exists by the addition of chromic oxide at above 35% carbon such as, even as high as 50-75% carbon. However, such high carbon composi-tions do not have~ the strength of lower carbon compositions 20 so that this invention of using not more than 35% carbon, such as 5-35% carbon with 5-30% chromic oxide, has the advantage of high strength with the same or better slag resistance of the high carbon compositions.

The compositions are therefore essentially comprised of alumina or aluminum silicate, carbon, chromium oxide and silicon metal.

~%~

The materials are mixed ~or use in the form of par-ticles which may vary from fines to coarse particles. A mix-ture of coarse particles or grains is referred to herein as an aggregate, for example an alumina aggregate.

Binders such as a plastic clay, coal tar pitch, phosphoric acid and the like are preferably present in the mix or may be added later. Where the original mixture con~
tains aluminous material in the form of a plastic aluminum silicate clay with or without calcined clay, this plastic clay 10 may serve both as the aluminous material and the binder.

The aggregate aluminous grains can be selected for a wide choice of materials including calcined clays, calcined bauxites, fused or tabular aluminas, i.e., aluminum silicates to pure aluminum oxides. The aggregate component can be of 1/2 inch siæe maximum graded to finer sizes. Preferably max-imum grain sizing is 3/8 inch by downs with 75% of the aggre-gate coarser than 20 mesh and at ].east 90% over 100 mesh.
The coarsest grain size can be as fine as 1/16 inch, but thi.s will not be as protective of the carbon component as aggre-20 gate in the 1/4 to 3/8 inch range.

The carbon content may be in the form of amorphous carbon or natural or synthetic graphite. Grain sizing may start as coarse as 1/~ inch by downs or coarser, but the bulk of it is preferably -30 mesh.

~ he chromic oxide is preferably present as the ses-quioxide (Cr203)-and -is preferably of the pigment grade for
4~3~

maximum effectiveness, that is, essentially sub-micron. How-ever, even coarser sizing has effectiveness, as for example, 100 mesh and coarser.

Silicon metal powder is added as an oxidation in-hibitor for the graphite and suitably may be -20 mesh, pref-erably finer.

Also, there may be included in the composition clays useful for workability, green binders for prefired strength, coal tar pitch for reduced penetrability and increased carbon 10 content. High alumina fines produce the most advantageous matrix, having at least 60% alumina content and grain sizing or -200 mesh, preferably -325 mesh. Further additions such as for extending shelf life of chemical bonded formulations or wetting agents are not precluded by suggested compositional ranges.

The refractory products made according to this des-cription may be in the form of ramming plastics, pressed shapes, drier granular ramming mixes, castables, gunning mixes, hand patching plastics, and vibration placement mixes.

The method of application determines grain sizing, water content, and type and amount of clay addition.

Our preferred range of formulation can be summar-ized as follows (dry basis):

% by weight Alumina or aluminum silicate aggregate 20-52 High alumina fines, -200 mesh 0-12 Carbon or graphite 5-35 Silicon metal powder 5-25 Chromic oxide 5-30 Fine plastic clays 0-15 Coal tar pitch 0-10 Green binders (lignosulfonates or aluminum sulfate) 0-7 High alumina cement 0-25 10 Phosphoric acid or aluminum phosphate 0-8 Water would be added in most cases, varying from about 12% for patching mixes, 10% for plastics, 5% for gra~u-lar ramming mixes, 3% for prewetted gun mixes to dry for cast-ables.

DET~ILED DESCRIPTION AND PREFERRED EMBODIMENTS

The following examples are provided to show a range of products intended by this invention.

A ramming plastic formulation was prepared as follows:
% by wei~ht Calcined bauxite (1/4" by downs) 47 -325 mesh calcined alumina 9 -30 mesh Mexican graphite 12 Pelletized coal tar pitch 5 Plastic ball clay 2 Western bentonite 6 Silicon metal powder 8 Chromi-~m oxide 8 Aluminum sulfate 3 1~2~9~1 Water was added to give a final moisture content of 10%.
This product has been manufactured by extrusion and slicing, placed into cartons, and has performed remarkably well against foundry slags over a wide variety of basicities.

A granular ramming mix was prepared as follows:
% by weight Calcined bauxite (1/4" by downs)51 -325 mesh calcined alumina 8 Mexican graphite (1/4" by downs)11 Plastic ball clay 8-1/2 Silicon metal powder 6-1/2 Chromium oxide 8-1/2 Phosphoric acid (75%) 6-1/2 Water was added to give a final moisture level of 6%. An ad-dition of approximately 0.25% of citric acid can provide ex-tended working life, particularly in warm environments.

A gunning mix was formulated as follows:
% by wei~ht Calcined bauxite (1/4" by downs)54 Chromium oxide 8-1/2 Silicon metal powder 6 Calcium aluminate cement (~70% A1203) 8-1/2 Mexican graphite ~1/4" by downs)12-1/2 Western bentonite 2 - - -100 mesh kyanite 8-1/2 ~4~1 This material is bagged dry, but can be prewetted with 3%
water addition just prior to gunning.

A product formulated for placement by vibration in a form, which can then be stripped for heating the lining so that it can soon be placed in service, is the following:
% by wei~ht Calcined bauxite (1/4" by downs)38.8 -325 mesh calcined alumina 7.8 Graphite (1/4" by 30 mesh) 9.7 Graphite (-30 mesh) 9.7 -35 mesh kyanite 7.8 Powdered silicon metal 9.7 Pelleti~ed coal tar pitch 5.8 Chromic oxide 7.8 Lignosulfonate water suspension 2.9 This material can be used at total water levels of 4-1/2 - 6%, providing a trade-off on ease of vibration vs. tendency to slump on removal of forms.

Effective economical formulations are based on useage of calcined refractory clay aggregates, such as are available commercially from sources in Missouri and Georgia with alumina contents ranging from 40-70%. A formulation of a ramming mix using calcined clay aggregate of 40-47% alumina is as follows:

~.Z94~l V/o by wei~ht Calcined clay aggregate (1/4" by downs) 50.5 -325 mesh calcined alumina 6.Q
-30 mesh natural graphite 12.0 Pelletized coal tar pitch 4.5 Plastic ball clay 4.5 Western bentonite 3.0 Silicon metal powder 7.5 Chromium oxide 9.0 Aluminum sulfate 3.0 Water is added to give a moisture in the 6-7% range. This material can be boxed as a granular product.

Increased resistance to slag pepetration is achieved by increasing carbon and chrome oxide contents, as well as in-creased silicon metal content to protect the carbon, as in the following formulation:
% by wei~ht Calcined clay aggregate (1/8" by downs) 20 -30 mesh natural graphite 17 Pelletized coal tar pitch 5 Fine plastic clays 12 Silicon metal powder 23 Chromium oxide 23 Water is added to give a moisture in the 6-7% range for a ram-ming mix, about 9% for an extrudable refractory plastic.
Higher moisture will provide hand patching or troweling con-sistencies.
_g_ Highly oxidation resistant versions are made using cal-cined bauxi.tic clay aggregates of 60-70% aluminum oxide, such as Mulcoa~ 60 and Mulcoa~ 70 sold by C-E Minerals Corporation:
% ~y wei~ht Calcined clay aggregate (Mulcoa 60 or 70) -4x20 mesh 50 -200 mesh Mulcoa 70 10 -30 mesh natural graphite 11 Fine plas tlC clays 8 Silicon metal powder 8 Chromium oxide 8 Lignosulfonate liquor, 50%
aqueous suspensi.on 5 Water is added to make a granular ramming mix in the 4-5~O
moisture range ~or maximum density and effectiveness.

EXAMPLE. 8 Higher purity systems are ormulated ~tlL tabular alumina and low ash carbon fines.
/O b~_weigl -6 mesh tabular alumina 44 Fine plastic clays 9 Silicon metal powder 8 Chromium oxide 28 -30 mesh coke fines 11 Water is add2d to produce a ramming mix or plastic consis-tency.

., ~;29~

_ Phosphate bonding is an effective means of obtaining high strength by preliminary heating to cure prior to use in service, providing initial impact resistance to molten metal flow after installation.
% bY weight -6 mesh tabular alumina 45 -30 mesh natural graphite 6 Western bentonite, -200 mesh 8 Silicon metal powder 8 Chromium oxide 27 75% concentrated phosphoric acid 6 Water is added as in previous example to achieve a ramming mix or plastic consistency.

In the specification and claims the term "high alumina" refers to an alumina-containing composition contain-ing at least 40% by weight alumina, preferably at least 60%

A1203 .

All percentages are in weight percent.

Claims (16)

THE CLAIMS
1. In a refractory composition comprising alumina or aluminum silicate refractory material, carbon and powdered silicon, the improvement of having chromic oxide and carbon present in the composition in amount sufficient to give greater resistance to slag over that of aluminous composition in which chromic oxide and carbon are absent, said carbon being present in up to about 35%
2. The composition in accordance with Claim 1 in which the alumina or aluminum silicate is present in at least 10% , the chromic oxide is present in 5-30%, the carbon is present in 5-35% and the silicon metal is present in 5-25%.
3. The composition of Claim 2 in which the alumina or aluminum silicate is present in 10-75% by weight.
4. The composition of Claim 3 in which a binding agent of plastic clay is present.
5. The composition of Claim 1 in which the carbon is graphite.
6. The composition of Claim 1 in which the aluminous material is present in at least 40% alumina.
7. A refractory composition comprising
8. The refractory composition of Claim 1 wherein the said composition is a plastic suitable as a ramming mix and comprises alumina or aluminum silicate aggregate, coal tar pitch, clay and aluminum sulfate.
9. The refractory composition of Claim 1 wherein the said composition is a gunning mix and the composition com-prises alumina or aluminum silicate aggregate, calcium alumin-ate cement, kyanite and bentonite.
10. The refractory composition of Claim 1 wherein the said composition is suitable for vibration placement and the composition comprises alumina or aluminum silicate ag-gregate, kyanite and coal tar pitch.
11. The refractory composition of Claim 1 wherein the composition is a granular ramming mix and the composition comprises alumina or aluminum silicate aggregate, phosphoric acid and clay.
12. The refractory composition of Claim 1 wherein the said composition comprises alumina in the form of cal-cined bauxite.
13. In a refractory composition comprising alumina or aluminum silicate refractory material, carbon and powdered silicon, the improvement of having chromic oxide and carbon present in the composition in amount sufficient to give greater resistance to slag over that of aluminous composition in which chromic oxide and carbon are absent.
14. The composition of Claim 13 wherein the alu-minous material comprises an alumina aggregate containing at least 40% alumina.
15. The composition of Claim 13 wherein the car-bon is graphite.
16. The composition of Claim 13 wherein the sili-con is present in amount sufficient to inhibit the oxida-tion of the carbon.
CA343,153A 1979-03-05 1980-01-07 Aluminous refractory composition containing carbon, silicon and chrome oxide Expired CA1129441A (en)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US06/017,270 US4210454A (en) 1979-03-05 1979-03-05 Aluminous refractory compositions containing carbon, silicon and chrome oxide
US17,270 1979-03-05
US88,549 1979-10-26
US06/088,549 US4233079A (en) 1979-10-26 1979-10-26 Aluminous refractory compositions containing carbon, silicon and chrome oxide

Publications (1)

Publication Number Publication Date
CA1129441A true CA1129441A (en) 1982-08-10

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Family Applications (1)

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CA343,153A Expired CA1129441A (en) 1979-03-05 1980-01-07 Aluminous refractory composition containing carbon, silicon and chrome oxide

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3053897A1 (en) * 2015-02-09 2016-08-10 Refractory Intellectual Property GmbH & Co. KG Formulation and process for the manufacture of a refractory product, a refractory product and the use therof

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3053897A1 (en) * 2015-02-09 2016-08-10 Refractory Intellectual Property GmbH & Co. KG Formulation and process for the manufacture of a refractory product, a refractory product and the use therof
WO2016128082A1 (en) * 2015-02-09 2016-08-18 Refractory Intellectual Property Gmbh & Co. Kg Batch composition for producing a refractory product, method for producing a refractory product, refractory product, and use of a refractory product
US11198647B2 (en) 2015-02-09 2021-12-14 Refractory Intellectual Property Gmbh & Co. Kg Batch for production of a refractory product, a process for the production of a refractory product, a refractory product as well as the use of a refractory product

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