CA1156686A - Alumino-silicate refractory brick - Google Patents

Abstract

ALUMINO-SILICATE REFRACTORY BRICK
Abstract of the Disclosure Carbon bonded refractory shapes in which the predominant refractory aggregate is andalusite, being characterized by the absence of substantial shrinkage after coking at 2000°F.

Description

ALUMINO-SILICATE REFRACTORY BRICK

sackground of the Invention -~ atural alumino-silicates which include, among others, clays, diaspore, kyanites, and bauxites, are the major ingredients for a large number of refractory brick currently manufactured. When the brick analyze less than about 50% A12O3, they are typically characterized in the art as fire clay brick. If they analyze more than 50%
A12O3, they are t~pically characterized as high alumina brick. Very generally, the properties of alumino-silicate brick vary with the percentage alumina they contain. This may be explained to a large extent by the quantity and type of mineral and glass phases formed by the alumino-silicate ;~
materials when the brick are burned.
As the alumina content of fire clay and high alumina brick is increased, resistance to load at elevated temperatures tends to increase. Also, resistance to spalling on rapid temperature change tends to increase.
These property changes are usually attributed to a reduction in quantity of low refractory and brittle silicate glasses present in the groundmass of the brick. On the other hand, increasing the alumina usually results in an increase in porosity making the brick physically more vulnerable to the chemical attack of metallurgical slags. In addition, bric~
higher in alumina tend to have less resistance to alkali vapors and shrink in service after cooling from high `~
temperatures.

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A few words here are appropriate as to what is meant by silicious groundmass. Alumina and silica present in alumino-silicate refractories react on firing to form, for the most part, the mineral mullite. Three moles of alumina react with two moles of silica. If the ratio of alumina to silica exceeds 3 to 2, the burned brick will also contain coroundum. If the ratio is less than 3 to 2, the burned brick will be substantially mullite and one of the crystalline or glassy forms of silica. Depending on the impurities present and the heat treatment, the silica will, to some extent, be in the form of a glass. The lower the alumina to silica ratio, the more SiO2 that will be present in a crystalline or glassy form. ~he amount of glass then relates to the amount of shrinkage encountered.
It is among the objects of the present invention to provide alumino-silicate refractory shapes characterized by the absence of shrinkage after coking at 2000F.
In accordance with the present invention, there is provided carbon bonded refractory shapes comprising from about 1 to 35%, by weight, carbon and the balance a non-basic refractory aggregate. The refractory aggregate consists essentially of at least about 75~, by weight, andalùsite.
Preferably, the balance of the refractory aggregate, if not all andalusite, is pure alumina or another aluminum silicate. The shapes preferably contain from about 0 to 30~, by weight, flake graphite. They may also contain less than about 7.5~, by weight, amorphous graphite and/or carbon black. Generally the shapes have between about 0.1 and 1~ volume expansion with andalusite compri~ing at least about 65% of the total weight of the batch. This expansion is important because it will prevent brick linings from becoming loose when cooling from high temperatures takes place.
Andalusite is a mineral having the same chemical formula (A12SiO5) as sillimanite and kyanite but with different physical properties.
A better understanding and further ~eatures and advantages of the practice of this invention will ~ecome 1 ~SB6~6 readily apparent to those skilled in the art by a study of the following detailed description and examples. It should of course, be understood that these examples are given by way of explanation, and not by way of limitation. All size gradings are according to the Tyler Series, unless otherwise specified. All chemical analyses, unless otherwise specified, are on the basis of an oxide analysis in conformity with the conventional practices of reporting the chemical content of refractory materials. All analyses should be considered typical. All parts and percentages are by weight.
The mixes of the examples were all fabricated into brick in the same manner. The refractory aggregate was size graded and mixed with a phenolic novolak r~esin.
The size graded batches were tempered in a muller-type mixer to render the batch pressible. The batches were pressed into brick at about 18,000 psi and the brick were dried at about 250F for about 12 hours. After cooling, the brick were submitted to tests to determine their dried density and volume change properties after coking. Various alumina-silicate shapes were prepared as shown in Table I
below.

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1 ~5~6 Mixes comprising predominantly a different alumino-silicate grain had shrinkage properties running from -0.4 to about -1.5~. The brick in which another refrac-tory material was added had shrinkages somewhere in between. The example mix No. 3 containing equal amounts of alumino-silicate grain and pyrophyllite expanded, but the expansion was accompanied by bloating.
Mixes 9 through 14 in Table II were made with the following andalusite to alumino-silicate grain ratios:
50-50, 55-45, 60-40, 65-35, 70-30; and 75-25.

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All of the mixes excep-t mix 14, with 75/25 andalusite-alumino silicate grain, exhibited volume shrinkage after coking.
Mixes in Table III below were made with andalusite as the only refractory agg,regate. However, the mixes contained from O to 30% flake graphite and up -to 5% of amorphous graphite and one with 5% carbon black.

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Mixes 15 through 18 contained 0 -to 30% flake graphite. As the amount of flake graphite increased from 0 to 30%, the amount of volume expansion after coking at 2000F, decreased from 1.2% to 0.4%. Mix 15 with only the resin present in addition to andalusite, would contain about 1.3% carbon derived entirely from the resin. Mixes 19 and 20 which contain 2.5% and 5%, respectively, amorphous graphite expanded after coking. Additional testing indicated that expansion was achieved when less than 7.5%
arnorphous graphite was used. Mix 21 which contains 5%
carbon black and no graphite, expanded after coking~ -The sizing of the refractory aggregates used in the above examples were as follows: -3+10 mesh --30 to 40%;
-10+28 mesh --lS to 25%; -28+65 mesh --10 to 15%; and the balance -65 mesh. The typical chemical analyses of the refractory materials used in the examples are set forth in Table IV below.

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The other materials used in the exernplary refractory compositions and not included in Table IV, are calcined alumina and tabular alumina. Both of these materials contain about 99~ A1203, the balance trace impurities and are well known in the art. Similarly, the crystoballite and volatilized silica are high purity silicious materials, i.e. 99% SiO2, and are also well known in the art.
Having thus described the invention in detail and with sufficient particularity as to enable those skilled in the art to practice it, what is desired to have protected by Letters Patent is set forth in the following claims.

Claims (7)

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:

1. Carbon bonded refractory shapes comprising from about 1 to 35%, by weight, carbon and the balance a non-basic refractory aggregate, said refractory aggregate consisting essentially of at least about 75%, by weight, andalusite, said refractory shapes being characterized by the absence of substantial shrinkage after coking at 2000°F.

2. Shapes of claim 1, in which the balance of the non-basic refractory aggregate is aluminum silicates or alumina.

3. Shapes of claim 1, which contains from about 0 to 30%, by weight, flake graphite.

4. Shapes of claim 1, which contain, at least, about 65% andalusite based on the total weight of the composition.

5. Shapes of claim 1, characterized by having between about 0.1% and 1% volume expansion after coking at 2000°F.

6. Shapes of claim 1, which contain up to about 5%, by weight, carbon black.

7. Shapes of claim 1, which contain less than about 7.5% amorphous graphite.