GB2024798A - Vibratable plastic refractory composition - Google Patents
Vibratable plastic refractory composition Download PDFInfo
- Publication number
- GB2024798A GB2024798A GB7922890A GB7922890A GB2024798A GB 2024798 A GB2024798 A GB 2024798A GB 7922890 A GB7922890 A GB 7922890A GB 7922890 A GB7922890 A GB 7922890A GB 2024798 A GB2024798 A GB 2024798A
- Authority
- GB
- United Kingdom
- Prior art keywords
- calcined
- refractory
- weight
- composition according
- alumina
- 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
Links
- 239000000203 mixture Substances 0.000 title claims abstract description 43
- NBIIXXVUZAFLBC-UHFFFAOYSA-N Phosphoric acid Chemical compound OP(O)(O)=O NBIIXXVUZAFLBC-UHFFFAOYSA-N 0.000 claims abstract description 22
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 14
- 239000005995 Aluminium silicate Substances 0.000 claims abstract description 12
- 235000012211 aluminium silicate Nutrition 0.000 claims abstract description 12
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 claims abstract description 12
- 229910000147 aluminium phosphate Inorganic materials 0.000 claims abstract description 11
- 229910001570 bauxite Inorganic materials 0.000 claims abstract description 10
- INJRKJPEYSAMPD-UHFFFAOYSA-N aluminum;silicic acid;hydrate Chemical compound O.[Al].[Al].O[Si](O)(O)O INJRKJPEYSAMPD-UHFFFAOYSA-N 0.000 claims abstract description 8
- 239000010443 kyanite Substances 0.000 claims abstract description 8
- 229910052850 kyanite Inorganic materials 0.000 claims abstract description 8
- 238000005496 tempering Methods 0.000 claims abstract description 8
- 239000007787 solid Substances 0.000 claims abstract description 7
- MXRIRQGCELJRSN-UHFFFAOYSA-N O.O.O.[Al] Chemical compound O.O.O.[Al] MXRIRQGCELJRSN-UHFFFAOYSA-N 0.000 claims abstract description 6
- 241000288673 Chiroptera Species 0.000 claims abstract description 3
- 239000011449 brick Substances 0.000 claims abstract description 3
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 claims abstract description 3
- 229910052863 mullite Inorganic materials 0.000 claims abstract description 3
- 229910052845 zircon Inorganic materials 0.000 claims abstract description 3
- GFQYVLUOOAAOGM-UHFFFAOYSA-N zirconium(iv) silicate Chemical compound [Zr+4].[O-][Si]([O-])([O-])[O-] GFQYVLUOOAAOGM-UHFFFAOYSA-N 0.000 claims abstract description 3
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 8
- 238000000034 method Methods 0.000 claims description 3
- 238000011065 in-situ storage Methods 0.000 abstract description 2
- 238000004519 manufacturing process Methods 0.000 abstract description 2
- 239000003795 chemical substances by application Substances 0.000 description 5
- 238000005266 casting Methods 0.000 description 4
- 239000011819 refractory material Substances 0.000 description 4
- 238000007792 addition Methods 0.000 description 3
- 239000000470 constituent Substances 0.000 description 2
- 239000012467 final product Substances 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 238000003860 storage Methods 0.000 description 2
- 230000009974 thixotropic effect Effects 0.000 description 2
- 238000005303 weighing Methods 0.000 description 2
- 239000000440 bentonite Substances 0.000 description 1
- 229910000278 bentonite Inorganic materials 0.000 description 1
- SVPXDRXYRYOSEX-UHFFFAOYSA-N bentoquatam Chemical compound O.O=[Si]=O.O=[Al]O[Al]=O SVPXDRXYRYOSEX-UHFFFAOYSA-N 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 239000004927 clay Substances 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 238000009415 formwork Methods 0.000 description 1
- 239000004615 ingredient Substances 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 239000000047 product Substances 0.000 description 1
- 238000004513 sizing Methods 0.000 description 1
- 239000003039 volatile agent Substances 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/10—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on aluminium oxide
- C04B35/101—Refractories from grain sized mixtures
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/66—Monolithic refractories or refractory mortars, including those whether or not containing clay
Landscapes
- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Ceramic Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Materials Engineering (AREA)
- Structural Engineering (AREA)
- Organic Chemistry (AREA)
- Compositions Of Macromolecular Compounds (AREA)
- Furnace Housings, Linings, Walls, And Ceilings (AREA)
- Compositions Of Oxide Ceramics (AREA)
- Ceramic Products (AREA)
Abstract
Vibratable plastic refractory compositions suitable for the production of refractory shapes and linings formed in situ, comprise, as the refractory solids therein, from 2 to 40% by weight of calcined kaolin and the balance, a non-basic calcined refractory aggregate, from 28 to 48% by weight of the refractory solids being -325 mesh (Tyler series). The refractory aggregate may be one or more of calcined bauxite, tubular alumina, calcined alumina, calcined fireclay, crushed refractory brick bats, zircon or mullite. The composition may also contain up to 5% by weight of crude kyanite, and 2-17% by weight of phosphoric acid, and some tempering water.
Description
SPECIFICATION
Vibratable plastic refractory composition
This invention is concerned with plastic refractory compositions for use in the production of refractory articles.
In the casting of refractory shapes from finely divided refractory materials, it is general practice to mix the refractory material with a binder and a suitable amount of a tempering agent, such as water.
The tempering agent is necessary so that the mixture will readily flow into the mould and take up the desired shape. After the shape has been moulded, it is usually fired at an elevated temperature to drive off the tempering agent and other volatiles, this resulting in a relatively porous product. In many applications, high density refractory shapes are required, and a reduction in the amount of tempering agent necessaryforthe mixture would be extremely helpful in increasing the density of the final product.
Another problem that has arisen in the casting of refractory shapes is the difficulty of removing the shape from the mould cavity. Quite often, the green refractory shape has a tendency to adhere to the mould walls so that it is impossible to remove the shape without damaging it.
It is also known to form refractory shapes by vibration forming and this procedure has a number of advantages over conventional casting. Thus the final product is normallydenserthan can be obtained with a castable composition. Conventional castable compositions must be allowed to set before the green shape is removed from the mould, while shapes formed by vibration casting can normally be removed as soon as the vibration is stopped. A plastic refractory composition suitable for placement by vibrating techniques is described, for example, in
U.S. Patent 4,056,398; this composition is based on one or more aluminous materials with carefully controlled amounts of bentonite and tetrasodium pyrophate added thereto.
We have now developed an improved vibratable plastic refractory composition that is thixotropic, both as made and after extended storage, that remains workable after extended storage, and that does not require the use of crude or raw, i.e. uncalcined, refractory material.
According to the present invention, there is provided a vibratable plastic refractory composition, which comprises as the refractory solids therein, from 2 to 40% by weight of calcined kaolin and the balance, a non-basic calcined refractory aggregate, from 28 to 48% by weight of the refractory solids being -325 mesh (Tyler series).
The composition is formed into shapes or into a refractory lining at its site of use by supplying a batch of the composition to an appropriately shaped enclosed area, that is a mould in the case of a refractory shape, and then applying mechanical vibrations to the batch. In the case of refractory shapes, the mould may be placed on a vibrating table. In the case of an in situ formed lining, immersible vibrators immersed in the batch may be used or the formwork
of the lining may be vibrated using an attached vib
rator.
The calcined refractory aggregate present in the
composition is selected on the basis of the application and service requirements and the choice of this constituent is not a critical feature of the invention.
Preferred aggregates are, for example, one or more
of calcined bauxite, tabular alumina, calcined
alumina, calcined fire-clay, crushed refractory brick
bats, zircon and mullite.
The critical constituent of the composition accord
ing to the invention is the calcined kaolin since it is this that makes the composition thixotropic and
imparts the vibratable characteristics. The smaller the amount of calcined kaolin within the range specified above, the longer must the composition be vibrated and the poorer the bond. The other critical feature of the composition is the correct proportion of -325 mesh fraction therein. This fraction is most conveniently provided by calcined alumina since it is the size in which it is commercially available. However, any of the non-basic ingredients can be used to supply all our a portion of this fraction as desired.
In one embodiment, the composition comprises, as the aggregate, from 45 to 85% by weight of cal ci ned bauxite and from 15 to 35% by weight of calcined alumina. In a preferred embodiment, the composition contains from 3 to 10% by weight of calcined kaolin.
It is preferred that the refractory solids of the composition should consist only of calcined refractory materials. However, up to 5% by weight of crude kyanite or equivalent material can be added, if desired, so as to impart shrinkage properties to the fired refractory shapes.
It is also preferred that the composition should contain concentrated phosphoric acid in an amount to provide P2O5 equivalent to that provided by 2 to 17% by weight of phosphoric acid. Water will also be present in the composition as a tempering agent, the amount thereof being dependent upon the amount of phosphoric acid and the particle sizing of the batch. It is preferred to use from 4 to 6% by weight of phosphoric acid and from 6 to 9% by weight of water.
A particularly preferred composition according to the invention comprises, by weight, 60 to 75% of calcined bauxite, 15 to 25% calcined alumina, up to 5% of kyanite, 3 to 10% calcined kaolin, and 4 to 6% phosphoric acid.
In order that the invention may be more fully understood, the following examples are given by way of illustration only. All parts and percentages are by weight; mesh sizes are in the Tyler series.
Example 1
A number of mixes were formed of calcined bauxite, calcined alumina, crude kyanite and calcined kaolin with phosphoric acid and water additions.
Three 9" x 2" x 2" bars were vibration cast from each mix and tested for bulk density and modulus of rupture, and the remainder of the mix was stored for 90 days. In mixes 1,2 and 3, -325 mesh fraction contents of from 30 to 38%, were studied. It was found that as the -325 mesh fraction increased, the water required for tempering increased.
The results obtained are shown in Table I below.
TABLEI Mix Designation:
Mix: 1 2 3 4 5 7
Calcined Bauxite 68% 68% 68% 63Y 73% 63%
Calcined Alumina 20% 20% 20% 25% 15% 25%
Crude Kyanite 5% 5% 5% 5% 5X 58 Calcined Kaolin 7% 7% 7% 7% 7% 7%
Plus Additions::
Phosphoric Acid 5.5% 5.5% 5.5% 5.5S 5-5Y 5.5S Water 6.4% 6.6X 6.7% 7.W 6.9S 7.0S Total -325 mesh fraction 30% 34% 38% 39% 28% 35%
Diameter of 2" Cylinder
Weighing 300 grams
After Yibrating 45 sec As Made: 3.20" 3.87" 3.75" 3.95" 3.37" 3.85" After 1 week: 2.80 3.32 3.23 3-35 3.50 3.36- After 30 Days: 2.68 2.77 2.52 2.69 2.90 3.05
After 60 Days: 2.33 2.03 2.02 2.26 2.85 2.65
After 90 Days: 2.19 2.00 2.00 2.30 2.90 2.75
Bulk Density, pcf (Av 3): 154 156 151 149 147 152
Modulus of Rupture, psi
(Av 3): 930 730 740 800 710 910
Example 2
A number of mixes, shown in Table II below, were prepared and tested. The total -325 mesh grain content ranged from 28 to 48% in mixes 7 to 15. These mixes were tempered with 7.5% to 8.4% water in 0.3% increments. At each water level, the as made
vibrability decreased somewhat, as measured by the
300 gram vibration test, and the shelf life deterior
ated somewhat as the -325 mesh grain increased.
Each mix was vibration cast into an 8" x 4" x 4" column. As soon as the mix knitted, the vibration was stopped, the mould sides were removed and the column was observed for slumping. Mixes 12 and 13, which were tempered with 8.1% water, were the only mixes which slumped. Mix 14, which was also tempered with 8.1% water, but contained 46% -325
mesh grain, showed no signs of slumping. Mix 15,
which was identical to mix 14, except that it was
tempered with 0.3% more water, did not slump.
TABLET II
Mix Designation:
Mix: 7 8 9 10 11 12 13 14 15
Calcined Bauxite -------------------------68%-------------------- Calcined Alumina -------------------------20 -------------------- Crude Kyanite --------------------------- 5 --------------------
Calcined Kaolin ------------------------- 7 ------------------
Plus Additions
Phosphoric Acid ----------5,5%---------------
Water --7.5%- 7.5% --- ----7.8%--------8.1%------ -8,4%-
Total -325 Mesh Grain 31S 39% 28% 37% 44% 31% 39% 46% 48%
Diameter of 2" Cylinder
Weighing 300 Grams
after Vibrating
45 Seconds as made: 2.99" 2.83" 3.26" 3.17" 2.70" 3.51" 3.58" 3.47" 2.78"
After 1 Week: 2.48 2.02 2.91 2:.72 2.01 3.01 3.12 2.91 3.37 After 30 Days: 2.18 2.01 2.54 2.01 2.00 2.84 2.84 2.00 2.66
After 60 Days: 2.29 2.00 2.79 2.00 ---- 2.92 2.75 ---- 2.44
After 90 Days: 2.24 ---- 2.34 ---- ---- 2.90 2.48 --- 2.15
Slumping, as Made: None None None None None Slight Very None None
Slight
Claims (10)
1. A vibratable plastic refractory composition, which comprises, as the refractory solids therein, from 2 to 40 /O by weight of calcined kaolin and the balance, a non-basic calcined refractory aggregate, from 28 to 48% by weight of the refractory solids
being -325 mesh (Tyler series).
2. A composition according to claim 1, in which
the aggregate is one or more calcined bauxite, tabular alumina, calcined alumina, calcined fireclay, crushed refractory brick bats, zircon or mullite.
3. A composition according to claim 1 or 2, which contains from 45 to 85% by weight of calcined baux
ite and from 15 to 35% by weight of calcined alumina.
4. A composition according to any of claims 1 to
3, which contains from 3 to 10% by weight of cal
cined kaolin.
5. A composition according to any of claims 1 to 4, which additionally comprises up to 5% by weight of crude kyanite.
6. A composition according to any of claims 1 to 5, which comprises from 2 to 17ago by weight of phosphoric acid.
7. A composition according to any of claims 1 to 6, which comprises tempering water.
8. Acomposition according to claim 1,which contains, by weight1 60 to 75% of calcined bauxite, 15 to 25% of calcined alumina, up to 5% kyanite, 3 to 10% calcined kaolin, and 4 to 6% phosphoric acid.
9. A method of forming a refractory shape or lining, which comprises supplying a batch of a composition according to any of claims 1 to 8 to an appropriately shaped enclosed area and then applying mechanical vibrations to the batch.
10. A vibratable plastic refractocomposition substantially as herein described in any of the
Examples.
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US92262778A | 1978-07-07 | 1978-07-07 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| GB2024798A true GB2024798A (en) | 1980-01-16 |
| GB2024798B GB2024798B (en) | 1982-08-04 |
Family
ID=25447349
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB7922890A Expired GB2024798B (en) | 1978-07-07 | 1979-07-02 | Vibratable plastic refractory composition |
Country Status (8)
| Country | Link |
|---|---|
| AU (1) | AU523294B2 (en) |
| BR (1) | BR7904166A (en) |
| CA (1) | CA1129443A (en) |
| DE (1) | DE2927993A1 (en) |
| FR (1) | FR2430284A1 (en) |
| GB (1) | GB2024798B (en) |
| IT (1) | IT1116886B (en) |
| MX (1) | MX153315A (en) |
Cited By (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0032602A1 (en) * | 1980-01-18 | 1981-07-29 | Lummus Crest S.A.R.L. | Refractory composition |
| EP0188688A2 (en) * | 1984-12-14 | 1986-07-30 | Martin & Pagenstecher GmbH | Refractory thixotropic vibration material and method and apparatus for the vibration lining of metallurgical vessels with the material |
| EP0247351A1 (en) * | 1986-05-07 | 1987-12-02 | Martin & Pagenstecher GmbH | Refractory thixotropic vibration material for the vibration lining of metallurgical vessels |
| FR2757503A1 (en) * | 1996-12-20 | 1998-06-26 | Steel Authority Of India Limit | Cement-free castable refractory composition |
| EP1534649A1 (en) * | 2002-06-17 | 2005-06-01 | American Clay Enterprises, LLC | Clay plaster |
| CN113912382A (en) * | 2021-10-18 | 2022-01-11 | 唐山市凯伦保温材料有限公司 | Light high-aluminum heat-insulation refractory brick and preparation method thereof |
Family Cites Families (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3547664A (en) * | 1967-12-13 | 1970-12-15 | Nalco Chemical Co | Refractory ramming mix |
| GB1477133A (en) * | 1974-05-29 | 1977-06-22 | Plibrico Co Ltd | Refractory products |
| US4056398A (en) * | 1977-03-31 | 1977-11-01 | Chicago Fire Brick Company | Plastic refractory composition suitable for placement by vibrating and the use thereof |
-
1979
- 1979-05-24 CA CA328,233A patent/CA1129443A/en not_active Expired
- 1979-05-30 AU AU47608/79A patent/AU523294B2/en not_active Ceased
- 1979-06-14 IT IT49419/79A patent/IT1116886B/en active
- 1979-07-02 GB GB7922890A patent/GB2024798B/en not_active Expired
- 1979-07-05 FR FR7917472A patent/FR2430284A1/en active Granted
- 1979-07-05 MX MX178359A patent/MX153315A/en unknown
- 1979-07-09 DE DE19792927993 patent/DE2927993A1/en not_active Ceased
- 1979-07-22 BR BR7904166A patent/BR7904166A/en unknown
Cited By (10)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0032602A1 (en) * | 1980-01-18 | 1981-07-29 | Lummus Crest S.A.R.L. | Refractory composition |
| EP0188688A2 (en) * | 1984-12-14 | 1986-07-30 | Martin & Pagenstecher GmbH | Refractory thixotropic vibration material and method and apparatus for the vibration lining of metallurgical vessels with the material |
| EP0188688A3 (en) * | 1984-12-14 | 1987-12-02 | Martin & Pagenstecher Gmbh | Refractory thixotropic vibration material and method and apparatus for the vibration lining of metallurgical vessels with the material |
| EP0247351A1 (en) * | 1986-05-07 | 1987-12-02 | Martin & Pagenstecher GmbH | Refractory thixotropic vibration material for the vibration lining of metallurgical vessels |
| FR2757503A1 (en) * | 1996-12-20 | 1998-06-26 | Steel Authority Of India Limit | Cement-free castable refractory composition |
| EP1534649A1 (en) * | 2002-06-17 | 2005-06-01 | American Clay Enterprises, LLC | Clay plaster |
| EP1534649A4 (en) * | 2002-06-17 | 2010-01-06 | American Clay Entpr Llc | Clay plaster |
| US7789960B2 (en) | 2002-06-17 | 2010-09-07 | Armin Croft Elsaesser | Clay plaster |
| US8007586B2 (en) | 2002-06-17 | 2011-08-30 | Armin Croft Elsaesser | Clay plaster |
| CN113912382A (en) * | 2021-10-18 | 2022-01-11 | 唐山市凯伦保温材料有限公司 | Light high-aluminum heat-insulation refractory brick and preparation method thereof |
Also Published As
| Publication number | Publication date |
|---|---|
| AU523294B2 (en) | 1982-07-22 |
| GB2024798B (en) | 1982-08-04 |
| BR7904166A (en) | 1980-03-18 |
| FR2430284A1 (en) | 1980-02-01 |
| CA1129443A (en) | 1982-08-10 |
| AU4760879A (en) | 1980-01-10 |
| MX153315A (en) | 1986-09-12 |
| IT1116886B (en) | 1986-02-10 |
| FR2430284B1 (en) | 1983-05-13 |
| IT7949419A0 (en) | 1979-06-14 |
| DE2927993A1 (en) | 1980-01-24 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| PCNP | Patent ceased through non-payment of renewal fee |
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