RU2815859C1 - Method and device for periodic production and continuous application of refractory composition on surface - Google Patents

Abstract

FIELD: chemistry.

SUBSTANCE: group of inventions relates to device and method of periodic production and continuous application of refractory composition. Device (2) comprises powder hopper (30) having an outlet, powder feed valve (38), powder feed valve controller (40), intermittent action reactor (10), product tank (60), product tank content sensor (66), controller (100), nozzle (80), water valve (54), water supply device (50) and water valve actuator (56). Valve (38) is located in the outlet hole of the hopper for powdery material. Regulator (40) is interconnected with the possibility of control with valve (38). Reactor (10) comprises inlet (12), door (22), intermittent-action reactor (16), mixing unit (17), intermittent-action reactor drive controller (18), intermittent-action reactor door (22) and actuator (24). At that powder bin (30) communicates with intermittent reactor inlet 12. Regulator (18) of intermittent-action reactor is interconnected with possibility of control with actuator (16) of intermittent-action reactor. Intermittent-action reactor drive (16) is mechanically interconnected with mixing unit (17). Actuator (24) of the door of the intermittent action reactor is interconnected with the possibility of control with door (22). Product container (60) has an inlet and an outlet. Inlet of product container (60) is configured to receive the contents of batch reactor (10) passing through door (22). Sensor (66) communicates with the amount of content (68) of container (60) for the product. Controller (100) comprises data processing/storage unit (112). Data processing/storage unit (112) communicates with sensor (66) of the content of the product container. Also, data processing/storage unit (112) communicates with possibility of control with valve regulator (40) for supply of powdered material. Besides, data processing/storage unit (112) communicates with intermittent-action reactor drive controller (18). Data processing/storage unit (112) communicates with possibility of control with actuator (24) of intermittent action reactor door. Nozzle (80) has an inlet hole and an outlet hole. Inlet of the nozzle receives an outlet from the outlet of container (60) for the product. Besides, nozzle inlet receives outlet of air hose (86). Air flow in air hose (86) is controlled by the air supply valve (88) and is controlled by the air supply valve actuator (90). Water supply device (50) passes through water valve (54) to water supply inlet (14) of intermittent action reactor (10) of intermittent action. Actuator (56) of the water valve is interconnected with the possibility of control with water valve (54). At that, data processing/storage unit (112) communicates with possibility of control with actuator (56) of water valve.

EFFECT: continuous production of refractory composition with different density values.

13 cl, 2 dwg

Description

State of the art

[1] The information described in this “Background of the Art” section does not necessarily represent recognized prior art.

[2] Tundishes and casting ladles are intermediate protective vessels used in the processing of metals and metal alloys. These containers contain a permanent refractory lining material that is resistant to high temperatures. Typically, these permanent linings are made of brick or refractories and contain from 50% to 70% Al ₂ O ₃ . Although these permanent lining materials are highly resistant to elevated temperatures, contact with molten metal and slag, and numerous heating and cooling cycles during molten metal processing can damage the permanent lining such that frequent replacement of the permanent lining is required. Thus, disposable linings formed from refractory materials suitable for dry vibration, troweling, shotcreting or spraying are formed on the permanent lining of a tundish or other molten metal processing vessel to extend the operational life of the permanent lining.

[3] In the spraying process to apply a refractory composition to a permanent lining, the refractory powder material is mixed with water and additives such as binders, wetting agents and dispersing agents to form a slurry. The pressurized suspension is fed to a spray nozzle, where compressed air is introduced to force the suspension out of the nozzle. The spraying process ensures uniform mixing because mixing occurs before the components reach the nozzle and mixing time is not limited by the contact time of the two components inside the spray nozzle.

[4] Mixing of water and refractory powder material can be performed in a batch process in which predetermined amounts of water and refractory powder material are placed in a container and subjected to procedures such as mixing. Batch processes provide ease of control over processing conditions such as the intensity of agitation, the energy supplied to the sample by agitation, and the amount of air enclosed in the sample. Mixing of water and refractory powder material can also be carried out in a continuous process in which water and refractory powder material are introduced into the inlet of the container and are combined and processed as they pass through the container to the outlet of the container. However, in a continuous process, it is difficult to control the process conditions. The spraying process is, for the most part, a continuous process, although the rate of application of the slurry may vary and may be interrupted for various reasons. The need for suspension during the application process is not constant. However, the atomization process depends on a constant supply of suspension.

[5] It has been found that properties such as density and porosity of certain spray refractory compositions depend on factors such as the presence of additives such as blowing agents in the suspension, in combination with the intensity of mixing of the suspension and the length of time for which the suspension is mixed . These factors are easier to control in a batch process than in a continuous process, but the need to produce successive batches of slurry for delivery to the spray nozzle requires that the flow rate of the slurry and the amount of slurry available be controlled so that slurry mixing can be controlled when batch mixing is used.

[6] WO199711802, Daussan, discloses a method and apparatus for producing and spraying an aqueous suspension. The aqueous suspension is mechanically mixed to foam and/or swell the surfactant, and the power and/or speed and/or time of mixing is adjusted to control the rate of foaming and/or swelling of the surfactant and thus vary the porosity of the sprayed coverings. However, no method or apparatus has been disclosed in which the start of a batch feeding process of a continuous coating process is controlled by data generated by a sensor on a storage vessel directly feeding the coating apparatus such that a continuous supply of slurry can be ensured.

[7] US4298288, Weisbrod, discloses a mobile concreting method and apparatus in which a combination of ingredients is fed in a controlled manner into a mixing device to produce a slurry. The suspension is transferred from the mixing device to the nozzle and from there to the surface to be coated. However, the Weisbrod method does not represent a batch processing method; Weisbrod's device is not designed to process a batch. Therefore, no method or apparatus is disclosed in which the start of a batch feeding process of a continuous coating process is controlled by data generated by a sensor on a storage container directly feeding the coating device such that a continuous supply of slurry can be ensured.

[8] EP0286513A1 ((DAUSSAN & CO [FR]) dated October 12, 1988 (1988-10-12)) relates to a method and apparatus for applying an insulating fire-resistant coating containing at least two layers of equal or unequal thickness, different compositions and with the same or different water content, onto surfaces such as the inside of a metallurgical vessel. The device contains a hopper for powdery material, a valve that allows or prevents flow from the hopper for powdery material, a mixing element that receives material from the hopper for powdery material, as well as water, a product container that receives material from the mixing element, a sensor that determines the content or a level of the mixed material in the sensor, a controller for regulating at least the amount of water in the mixture, and a nozzle for applying the mixture. This device can produce formulations of preselected densities by varying the amounts of components introduced into the batch process, but cannot control the mixing energy supplied to the batch process over a period of time to produce formulations of preselected densities.

[9] DE4217373A1 ((KLAUS OBERMANN GMBH [DE]) dated December 16, 1993 (1993-12-16)) discloses a device for preparing mixtures or suspensions containing one liquid component (for example, water-cement mixtures, water-based bentonite suspensions, etc.) containing a mixer into which metered quantities of liquid and solid (powdered material, granulate, paste or suspension) components are supplied from separate supply sources and followed by a pump for transporting the final mixture into a pipeline leading to the container for supply or consumer. The mixer is a continuous mixer into which liquid and solid components are continuously supplied in quantities corresponding to the final mixture released through the pump. The device is not configured to operate a batch process, whereby, for example, a controlled amount of energy from the mixture can be supplied to the batch over a specified period of time.

[10] Accordingly, the development of a device and process that provides the benefits of both batch and continuous processes in the combination of spray applied refractory components would be advantageous and would allow continuous production of a product in which different densities can be achieved with a single composition.

SUMMARY OF THE INVENTION

[11] The invention described herein relates to devices and methods for the batch production of refractory suspensions and their continuous spray application.

[12] An exemplary apparatus of the present invention comprises a batch reactor configured to mix the components of a composition to produce a refractory slurry. The batch reactor communicates with a plurality of feed inlets. The flow or passage through each reactor feed inlet is controlled by an actuator that controls, for example, a pump, feeder or valve mounted on the corresponding inlet. The feed inlets provide communication between associated feed lines or storage vessels through associated actuators to the batch reactor. The batch reactor contains a reactor outlet which, when positioned and open, discharges the contents of the reactor vessel into the product vessel. The product container includes a product container outlet through which the contents of the product container can flow.

[13] The product container outlet is in fluid communication with the pump of the coater, which is in fluid communication with the coater via the product inlet of the coater. An air inlet, the flow through which is controlled by an air supply valve, is also in communication with the coating apparatus. Inside the coater, the air inlet and the product inlet merge to form an outlet that passes through the nozzle of the coater.

[14] The controller accepts input from the human interface and from sensors. The product quantity sensor provides measurements of the quantity of product in the product container to the controller. Flow sensors provide measurements of the flow rate through the air inlet and product inlet. The controller controls the actuators that control the flow or passage through the reactor feed inlets. The controller controls the actuators that control the starting, stopping, and speed or intensity of processes, such as mixing, in a batch reactor. The controller controls an actuator attached to the outlet of the batch reactor, which controls the opening and closing of the outlet of the batch reactor. The controller controls an application pump actuator in communication with the coater pump, which starts, stops, or controls the speed of product movement through the actuator pump. The air inlet actuator starts, stops, or controls the flow of air through the air inlet.

[15] The process of applying the refractory composition according to this invention is carried out as follows. Feed inlets are located to receive formulation components into the batch reactor. The information is entered into the controller, the information including batch composition, batch mixing time, and batch mixing speed. The controller controls the actuators for introducing the composition components into the batch reactor. The controller controls the actuators to start batch production, regulate batch production, and stop batch production when the process is completed. When batch production is completed, the controller receives input from the product container quantity sensor and determines whether the contents of the batch reactor can be placed into the product container. If the contents of the batch reactor can be placed in a product container, the controller signals the actuator to open the batch reactor outlet and the processed batch is transferred to the product container and can be transported by a pump to deliver the slurry to the nozzle. Then you can start spraying and processing a new batch.

[16] A continuous supply of the batch-produced composition can be maintained as follows.

[17] The controller maintains or collects information about the on/off status of the slurry pump, the presence or absence of a batch in the batch reactor, the batch size of the batch reactor, the on/off status of the batch reactor drive, the remaining mixing time for the batch in the reactor batch operation, the amount of slurry in the product container, and whether the batch and continuous application device is initialized (i.e., the product container is partially or completely filled with slurry before spraying begins).

[18] If the device is not initialized and if the slurry pump is not pumping, no new batches will be started.

[19] If the slurry pump is pumping, the amount of slurry in the product container is monitored on a regular basis, and the capacity of the product container is obtained. Product vessel capacity represents the amount of slurry that can be taken from the batch reactor; it is the result of subtracting the amount of slurry in the product vessel from the amount of slurry that can be taken out of the batch reactor when the product vessel is empty. The capacity of the product container is compared with the amount of slurry in the batch reactor. The controller performs actions regarding the comparison of the capacity (VM) in the product container with the amount of suspension in the batch reactor (RPR), the presence/absence of a batch (B/N) in the batch reactor, the on/off state of the batch reactor drive (BRDR) and remaining mixing time (RMT) for the batch in the batch reactor.

[20] For BM > RPD, RPD: N, and PRPD OFF, the formulation components are introduced into the batch reactor, and PRPD ON to initiate batch processing. The situation in which VM > RPD, RPD: N and PRPD: ON does not occur during normal operation.

[21] For VM > RPD, RPD: D, PRPD OFF and OBC > 0, PRPD ON to complete periodic processing. When batch processing is completed, the DPRP is turned OFF and the processed batch is discharged from the batch reactor.

[22] For VM > RPD, RPD: D, PRPD ON and OBC > 0, the PRPD remains ON until batch processing is completed, while the PRPD is OFF and the processed batch is discharged from the batch reactor.

[23] For VM > RPD, RPD: D, PRPD ON and OBC = 0, PRPD OFF, and the processed batch is discharged from the batch reactor.

[24] For VM > RPD, RPD: D, PRPD OFF and OBC = 0, the processed batch is unloaded from the batch reactor.

[25] For VM < RPD, RPD: N and PRPD OFF, no action is taken until VM > RPD. The situation in which VM < RPD, RPD: N and PRPD ON does not arise during normal operation.

[26] For VM < RPD, RPD: D, PRPD ON and OBC > 0, PRPD OFF while VM > RPD.

[27] For VM < RPD, RPD: D, PRPD OFF and OBC > 0, PRPD remains OFF as long as VM > RPD.

[28] For VM < RPD, RPD: D, PRPD ON and OBC = 0, PRPD OFF, and the processed batch remains in the batch reactor.

[29] For VM < RPD, RPD: D, PRPD OFF and OBC = 0, PRPD remains off and the processed batch remains in the batch reactor.

BRIEF DESCRIPTION OF GRAPHIC MATERIALS

[30] Various features and characteristics of the present invention described in this specification may be better understood by reference to the accompanying drawings, wherein:

[31] in FIG. 1 shows a schematic representation of a device for the production and application of a refractory suspension; And

[32] in FIG. 2 shows a schematic representation of the data acquisition and control elements of a device for the production and application of a refractory suspension.

[33] The above features and characteristics, as well as other features and characteristics, will become apparent to the reader upon consideration of the following detailed description of the invention.

DESCRIPTION OF THE INVENTION

[34] The refractory compositions described herein provide work linings or other refractory structures that provide antioxidant barrier properties when used in metallurgical vessels. As used herein, including in the claims, the term "work lining" means the innermost refractory layer that contacts the molten metal contained in the metallurgical vessel. As used in this specification, including in the claims, the term “metal” means both metals and metal alloys. As used herein, the expression “communicated to receive” is used to describe a device or device element that receives data, such as data in electronic form, sent from another device or device element. As used herein, the expression “measurably communicated” is used to describe a device or device element that measures, analyzes or otherwise extracts information from another device, device element, device content, or sample material. As used herein, the expression “controllably communicated” is used to describe a device or device element that communicates commands to another device or device element. As used herein, the expression “communicates with” is used to express contact, which may be either indirect, through an intermediate element, or direct, in which there is no intermediate element.

[35] In FIG. 1 is a schematic diagram of the configuration of a batch production and continuous application apparatus 2 comprising a batch reactor 10 . The batch reactor 10 includes a port 12 for supplying powdery material and an inlet 14 for supplying water. The batch reactor 10 is equipped with a batch reactor drive 16 that is coupled to, mechanically coupled with, and capable of driving a mixing assembly 17 , which may include mixing, combining, shaking, or stirring elements, such as paddles and paddles, within the reactor 10 periodic action. The drive 16 of the periodic reactor is regulated by the regulator 18 of the drive of the periodic reactor; The regulator 18 of the drive of the periodic reactor communicates with the possibility of control with the drive 16 of the periodic reactor. The batch reactor drive controller 18 can start, stop, or change the speed of the mixing unit 17 in the batch reactor 10 . The load measurement sensor 20 provides measurements of the weight of the contents of the batch reactor 10 . The load measurement sensor 20 communicates with the possibility of measurement with the reactor 10 of periodic action.

[36] The contents of the batch reactor are removed through the batch reactor door 22 , which is controlled by the batch reactor door actuator 24 ; The batch reactor door actuator 24 opens and closes the batch reactor door 22 . The batch reactor door 22 is the outlet of the batch reactor 10 . The actuator 24 of the batch reactor door is in controllable communication with the door 22 . A 5-port, 2-way directional valve in communication with the batch reactor door actuator 24 may be used to control the batch reactor door 22 .

[37] The powder material hopper 30 is equipped with a powder material hopper vibration device 32 , an adjustable powder material hopper vibration device actuator 34 . The powder material hopper vibration device 32 may be attached to the powder material hopper 30 or may be in communication with the powder material hopper 30 . The actuator 34 of the powder hopper vibration device is in controllable communication with the powder material hopper vibration device 32 . The powdered material is supplied from the powdered material hopper 30 through the powdered material supply valve 38 , controlled by the powdered material supply valve regulator 40 , to the inlet of the powdered material feeder 42 having an inlet and an outlet, containing a motor, and comprising a material transfer device such as like an auger or worm. The powder feeder 42 is controlled by the powder feeder controller 44 . The powder feeder controller 44 ensures that a selected amount of powder material is transferred to the batch reactor 10 . Measurements from the load measurement sensor 20 are processed and supplied to the powder feeder controller 44 to load the batch reactor 10 with a predetermined amount of powder material. The powdered material exiting the powdered material feeder 42 is supplied to the powdered material supply port 12 of the batch reactor 10 . As the powder material supply valve 38, a 5-port 2-way directional valve can be used. The powder material supply valve 38 and the powder material supply valve regulator 40 may be combined as a single unit. The powder material hopper 30 has an outlet; wherein the powder material supply valve 38 may be located in or adjacent to the outlet of the powder material hopper; The powder material supply valve controller 40 is in controllable communication with the powder material supply valve 38 . The outlet of the powder material hopper 30 communicates with the inlet of the batch reactor.

[38] The water supply line 50 extends past or through the water flow sensor 52 and through the water valve 54 controlled by the water valve actuator 56 into the water inlet 14 of the batch reactor 10 . The water valve actuator 56 moves a selected amount of water into the batch reactor 10 . The water valve actuator 56 is in controllable communication with the water valve 54 . The water flow speed sensor 52 communicates with the possibility of measurement with the water supply device 50 . The water flow sensor 52 may include a water rotor and a Hall effect sensor.

[39] After mixing, the contents of the reactor10 batch action is fed into the container60 for product through the door22 batch reactor. Capacity60 for the product has an inlet and outlet; container inlet60 for the product is configured to receive the contents of the reactor10 periodic action through the door22. In the configuration shown, the door22 located above the inlet into the container60 for the product, and the contents of the reactor10 periodic action passing through the door22, falls into the container60 for the product. Capacity60 for the product contains a vibration device62 product containers controlled by an actuator64 vibrating device for the product container. Vibration device62 product containers can be attached to the container60 for the product or can communicate with the container60 for the product. Actuating mechanism64 vibrating device of the container for the product communicates with the possibility of control with the vibrating device62 containers for the product. Capacity60 for the product contains a measuring sensor66 contents of product container to measure quantity68 suspension inside the container60 for the product. Sensor66 the contents of the product container are measurably communicated with the contents68 containers60 for the product. Capacity60 for a product may contain a lower part in the form of a truncated cone with a minimum radius, located next to the outlet of the container60for the product.

[40] The contents of the product container 60 are supplied to the inlet of the slurry pump 70 . The slurry pump 70 has an inlet port and an outlet port. The inlet of the slurry pump 70 communicates directly or indirectly with the outlet of the product container 60 . The slurry pump 70 includes a motor and a material moving configuration such as a screw. The slurry pump 70 is controlled by the slurry pump controller 72 . The slurry pump controller 72 is in controllable communication with the slurry pump 70 .

[41] The outlet of the slurry pump 70 extends through the slurry hose 76 to the nozzle 80 . The outlet of the slurry pump 70 communicates with the inlet of the nozzle 80 .

[42] Air flows through air hose 86 , through air valve 88 controlled by air valve actuator 90 , and past or through air velocity sensor 92 to nozzle 80 . The air velocity sensor 92 may be an analog device or a digital device.

[43] Through nozzle 80, air is introduced into the slurry flow just before the exit point. The suspension is pushed out from the exit point of the nozzle 80 . The nozzle 80 has an inlet port and an outlet port. The nozzle inlet receives an outlet from the outlet of the product container 60 ; The inlet port of the nozzle accepts the outlet of the air hose 86 . The nozzle inlet may be divided into separate chambers, including a chamber for receiving the outlet from the outlet of the product container 60 , and a chamber for receiving the outlet from the air hose 86 ; in this configuration, the product container chamber and the air chamber are in contact within the nozzle 80 for communication with the nozzle outlet. The air flow in the air hose 86 is controlled by the air supply valve 88 and is controlled by the air supply valve actuator 90 .

[44] The batch production and continuous application apparatus 2 is controlled by a controller 100 comprising a display 102, a human-machine interface (HMI) controller, a control panel 104 , a command port 106 , a data acquisition port 108, and a processor 112. The HMI display 102 interface is a device that provides interaction between a person and a machine; it can receive and execute operator control commands and can provide process status information to the operator. The control panel 104 is a surface that may contain manual controls, such as switches, buttons, knobs, or keypads, to operate the device, and may contain display components, such as instrumentation and video screens, to provide information about the status of the device.

[45] In FIG. 2 is a schematic representation of the controller 100 and the device controller connections 101 of FIG. 1. The controller includes a human-machine interface display 102 and a control panel 104 for viewing process data and entering commands, respectively. The human-machine interface display 102 and the control panel 104 may be separate devices or an integrated device.

[46] The controller 100 includes a command transmission port 106 . The controller is connected via command transmission port 106 to the batch reactor drive regulator 18 , the batch reactor door actuator 24 , the powder material hopper vibration actuator 34 , the powder material supply valve regulator 40 , the powder material feeder regulator 44 , the water actuator 56 valve, product container vibrating device actuator 64 , slurry pump controller 72 , and air supply valve actuator 90 .

[47] The controller 100 includes a data acquisition port 108 . The controller communicates via data collection port 108 with a load measurement sensor 20 , a water flow rate sensor 52 , a product container measurement sensor 66 , and an air flow rate sensor 92 .

[48] The controller 100 includes a data processing/storage unit 112 that receives data input and communicates in receiving manner with a human-machine interface display 102 , a control panel 104 , a load sensing sensor 20 , a water flow rate sensor 52 , and a container contents measuring sensor 66 for the product and air flow speed sensor 92 . The data processing/storage unit 112 performs calculations and logical operations on the data coming from the interface 102 , the control panel 104 , the sensors 20 , 52 , 66 and 92 , and the data stored internally. Commands based on the results of calculations and logical operations are issued through the command transmission port to regulators and actuators 18 , 24 , 34 , 40 , 44 , 56 , 64 , 72 and 90 . The data processing/storage unit 112 is in controllable communication with controllers and actuators 18 , 24 , 34 , 40 , 44 , 56 , 64 , 72 and 90 .

[49] Connections 101 between the controller and various actuators and sensors may be made by wire, by fiber optic cable, or by wireless transmission. Devices can communicate via Ethernet/IP.

[50] The device described herein may employ special components.

[51] Reactor10 periodic action may take the form of a closed container containing an internal mixing unit configured to mix the contents of the reactor10 periodic action. Reactor10 periodic action may contain a drive16 batch reactor such as a 7500 W gear motor coupled to a variable frequency drive and mixing unit17which may comprise mixing blades, such as the corner mixing blades of a corner vortex batch reactor, connected to a rotating shaft driven by a drive16 batch reactor. Reactor10 periodic action may take the form of a drum-type paddle mixer. Reactor10 periodic action, formed from a drum for containing a suspension with a capacity of 0.25 cubic meters. m, holds a 90-kilogram batch of refractory suspension. Pneumatic piston can be used as an actuator24 batch reactor doors. Door22batch reactor is usually located at the bottom of the reactor10 periodic action. Capacity60 for the product can be located under the door22 batch reactor so that the finished batch can be unloaded from the reactor10 periodic action in container60 for the product. When powdered material and water are present, the mixer blades rotate at a specific speed and time, which are controlled by the process according to the operator's setpoints. By introducing low or high shear and increased mixing energy into a batch process over a period of time, the physical properties of the slurry can be altered until the desired result is achieved. The motor power can be 7500 W or more; it was found that a motor power of 7500 W or more was required to reduce the density of a refractory batch. Drive unit16 batch reactor may be configured to supply at least 7500 W of mechanical power to the mixing unit17.

[52] The load sensor 20 may be a load sensor system such as a hydraulic load cell, a pneumatic load cell, or a strain gauge load cell. A system with a capacity of 9000 kg can be used.

[53] The powder material hopper vibration device 32 , controlled by the powder material hopper vibration device actuator 34 , can be used with the powder material hopper 30 to eliminate material arching, material jamming, and uneven flow. The powder hopper vibration device 32 may be electrically or pneumatically driven. Typically, the powder hopper vibrating device 32 is in physical contact or communication with the powder hopper 30 . The 1800 kg storage hopper may be suitable for use as the powder material hopper 30 in the batch production and continuous application apparatus 2 .

[54] The powder feeder 42 may include a motor, such as a 750 W electric gear motor coupled to a variable frequency drive. Feeding of powdered material can be done using a conveyor such as a 10 cm worm type auger.

[55] The water valve actuator 56 for the water valve 54 may be a 2-way fluid solenoid.

[56] The slurry level sensor 66 may be a laser distance sensor. It may be located inside or above the product container 60 . It may be oriented to the output port of the product container 60 .

[57] The slurry pump 70 may include a motor, such as a 9300 W electric gear motor coupled to a variable frequency drive. The slurry pump 70 may also include a hopper vane feeder and a rotor-stator assembly, as well as a vibrating air motor. A hopper for containing the suspension, which can have a volume of 0.17 cubic meters. m, may be positioned to receive the suspension from the product container 60 . When this configuration is activated and slurry is present, the pump rotates at various speeds to deliver slurry from the holding hopper using a paddle feeder forcing the slurry into the rotor-stator assembly where the slurry is uniformly forced out through the pump outlet for discharge. The vibrating air motor levels the slurry in the slurry hopper such that the container contents sensor 66 obtains an accurate measurement of the amount of slurry 68 in the product container 60 .

[58] In a typical configuration, spray nozzle 80 comprises a 30 cm x 2.5 cm diameter piece of hydraulic hose connected to a cast aluminum nozzle head with an integrated spray air tube and a 12 mm nozzle rubber spray cap. When the slurry is pumped into the nozzle, mild compressed air is introduced into the slurry flow just before the exit point (12mm diameter hole concentric with the spray air tube). This action creates a conical shape of the suspension, which is then applied to the surface.

[59] The air valve actuator 90 for the air valve 88 may be a two-way fluid solenoid.

[60] Machine control can be achieved by using an Allen Bradley Micrologixs 1400 PLC controller as the controller100 and C-More HMI display as display102 human-machine interface. A human-machine interface display is a screen that allows a user to interact with a device, such as a device that conducts or controls an industrial process.

[61] Formulations that can be used with the disclosed device include alumina compositions containing calcium aluminate cements and dispersing agents. While the batch production and continuous application apparatus produces a range of densities of refractory slurry from a single mixture of components, it also produces successive batches of refractory slurry with varying water contents.

[62] The batch production and continuous application device 2 can be configured to prevent the production of an excess amount of suspension. If the product vessel 60 cannot keep up with the batch reactor 10 , the product vessel contents sensor 66 identifies excess slurry in the product vessel 60 (for example, by providing information to the data processing/storage unit 112 to determine that the product vessel 60 is cannot accommodate the contents of the batch reactor 10 ), and the data processing/storage unit 112 places the batch reactor 10 in a “holding” state until a sufficient amount of slurry is displaced from the product container 60 so that the additional batch from the batch reactor 10 and completely contain it in the product container 60 . The "hold" state may include stopping the mixing process and/or stopping the movement of the slurry from the batch reactor 10 to the product vessel 60 . This may be accomplished in a device configuration 2 in which the data processing/storage unit 112 is configured to process data received from the product container contents sensor 66 to control the batch reactor drive controller 18 and the batch reactor door actuator 24 .

[63] The batch production and continuous application apparatus 2 may also be configured such that if the product vessel 60 cannot keep up with the batch reactor 10 , the product vessel contents sensor 66 identifies excess slurry in the product vessel 60 (e.g. , by providing information to the processing/storage unit 112 to determine that the product container 60 cannot accommodate the contents of the batch reactor 10 ), and the processing/storage unit 112 deactivates the movement of the powdered material, water and other formulation components into the batch reactor 10 operation until a sufficient amount of slurry is displaced from the product vessel 60 such that an additional batch can be discharged from the batch reactor 10 and completely contained in the product vessel 60 . This may be accomplished in a device configuration 2 in which the data processing/storage unit 112 is configured to process data received from the product container contents sensor 66 to control the powder valve controller 40 , the water valve actuator 56 , and the drive controller 18 . batch reactor. The data processing/storage unit may also process data received from the product container contents sensor 66 to control the batch reactor door actuator 24 .

[64] The batch production and continuous application apparatus 2 may also be configured to prevent interruption of the application process due to a lack of suspension in the product container 60 . In one configuration, if the product container contents sensor 66 detects a predetermined minimum amount or low level of slurry in the product container 60 , a signal is sent to the controller HMI display 102 . The operator then reduces the maximum speed (rpm) of pump 70 to deliver the slurry. In another configuration, if the product container contents sensor 66 detects a low slurry level in the product container 60 , the data processing/storage unit 112 performs a calculation based on the cumulative slurry utilization rate (C/U) based on the data obtained from the slurry amount 68 (C) in the product container 60 and the remaining mixing time (RMT) of the batch in the batch reactor 10 . If (C/B) > (C/(OBC)), the slurry pump controller 72 reduces the maximum slurry utilization rate to be less than (C/(OBC)).

[65] Structurally, the outlet of the powder material hopper 30 communicates with the inlet of the powder material supply valve 38 . The outlet of the powder material supply valve 38 communicates with the inlet of the powder material feeder 42 . The outlet of the powder material feeder 42 communicates with the powder material supply port 12 of the batch reactor of the batch reactor 10 . The water supply device 50 extends from the water source through the water valve 54 to the water supply inlet 14 of the batch reactor. The outlet of the batch reactor 10 communicates with the inlet of the product container 60 . The outlet of the product container 60 communicates with the inlet of the pump 70 for supplying the suspension. The outlet of the slurry pump 70 communicates with the inlet, or said inlet, of the nozzle 80 . The air supply line extends from the compressed air source through the air supply valve 88 and the air hose 86 to the inlet port, or said inlet port, of the nozzle 80 . The air from the air hose 86 and the product or contents of the slurry hose 76 are combined in the nozzle 80 and sprayed from the nozzle 80 .

[66] The method of producing and continuously applying a refractory composition to a surface using the batch production and continuous application device 2 is carried out as follows. The dry components of the composition are introduced into the hopper 30 for powdered material. The powder bin vibration device 32 can be activated by a powder bin vibration device actuator, which can be controlled by the data processing/storage unit 112 of the controller 100 through the command port 106 . The operator enters batch production parameters and commands, such as batch size, water content, solids content, mixing time and mixing speed, and batch start command, into the controller 100 via the controller HMI display 102 , control panel 104 , or other Input Devices. The controller 100 transmits a command through a command port 106 to the powder material supply valve regulator 40 and the powder material supply valve 38 and/or the powder material feeder regulator 42 to move dry components from the powder material hopper 30 to the inlet of the powder material feeder 42 . The dry components move from the outlet of the powder feeder 42 to the powder feed port 12 of the batch reactor and into the batch reactor 10 . The amount of powdery material transferred from the powdery material hopper 30 to the batch reactor 10 can be determined by the difference before and after the transfer by the load sensing sensor 20 . Thus, data from the load measurement sensor 20 can be used to control the movement of powdered material from the powdered material hopper 30 to the batch reactor 10 .

[67] The controller 100 transmits a command through the command transmission port 106 to the water valve actuator 56 and the water valve 54 for introducing water from the water supply device 50 into the batch reactor 10 . The amount of water transferred to the batch reactor 10 can be obtained by the water flow rate sensor 52 or determined by the difference, before and after movement, by the load sensing sensor 20 . Thus, data from the load measurement sensor 20 can be used to control the supply of water to the batch reactor 10 . Additional liquid or dissolved components may be introduced into the water supply device 50 or may be introduced into the batch reactor 10 from a separate container containing a valve and a valve actuator. Controller 100 determines the amount of material (or mass or density) in batch reactor 109 based on data received from sensor 52 and/or sensor 20 .

[68] The process of placing batch components into the batch reactor 10 is called "loading". When all components of the batch have entered the batch reactor 10 in the selected quantities, the controller 100 transmits a command through the command port to the batch reactor drive controller 18 to activate the batch reactor drive 16 to begin the mixing process in the batch reactor 10 . The controller 100 controls the start, stop, pause, duration and intensity of mixing. The controller 100 also calculates and maintains the remaining mixing time value. The mixing intensity is related to the rotation speed of the mixing configuration and the configuration of the mixing assembly 17 , such as mixing paddles or paddles, within the batch reactor 10 . The batch reactor 10 may contain any known type of stirrer. The batch size, mixing time, and mixing intensity of the component combination can be selected based on a calibration table that specifies the batch size, mixing time, and mixing intensity combinations of a particular component combination to produce a slurry at a given density.

[69] During batch mixing, controller 100 monitors the contents 68 of product container 60 . The product container contents sensor 66 transmits this information to the controller 100 through the data collection port 108 so that the amount of product in the product container 60 can be determined by the data processing/storage unit 112 . If product container 60 cannot accommodate the batch being mixed, controller 100 commands batch reactor drive actuator 18 to suspend batch mixing until product container 60 can accommodate the batch. If a batch does not mix and the product container 60 cannot accommodate the next batch to be mixed, combining the components and starting batch mixing is delayed until the product container 60 can accommodate the batch. Typically, process vessel 60 will accommodate at least two batches produced in batch reactor 10 such that there is no need to stop the batch mixing process while the original batch is being produced.

[70] When batch mixing is complete and the contents of the batch mixer 10 can be placed in the product container 60 , the controller 100 commands the batch reactor door actuator 24 to open the batch reactor door 22 . Thus, the contents of the batch mixer 10 are transferred to the product container 60 . The product container 60 may include a product container vibration device 62 in communication with a product container vibration device 64 actuator. The product container vibration device 62 may be electrically or pneumatically driven. The product container vibration device 62 ensures that the slurry remains in contact with and exits the product container 60 exit port. The presence of product in the product container 60 , which can be measured by the product container contents sensor 66 , may be received by the controller 100 and used by the data processing/storage unit 112 to instruct the product container vibrator actuator 64 to begin operating the container vibrator 62 for the product.

[71] The part of the process that occurs before spraying begins may be called system initialization. When the product is in the container60 for the product, the suspension may begin to spray. Controller101 transmits commands to the controller72 suspension pump to control pump injection speed70 for feeding a suspension for feeding a product or suspension into a nozzle80 and actuator90 air supply valve to control the rate of air flow through the valve88 for air supply and air hose86 for supplying air to the nozzle80. The suspension flows from the pump70 for supplying suspension through a hose76 for supplying suspension to the nozzle80; air flows through the air hose86 to the nozzle80. Sensor92 air flow rate transmits information about the air flow rate to the controller100; controller100 transmits commands to the controller72suspension pump, actuator90air supply valve to equalize flow rates through the pump70 for supplying suspension, and an air hose86so that the sludge is sprayed from the nozzle80 under a given pressure. The operator can adjust the pump's pumping speed70 to supply the suspension at any time during the process by entering a command via the display102 controller HMI or via panel104 control, or manipulating the actuator90 valve for air supply; in certain device configurations, pump injection speed70 to supply the suspension is maintained in a given ratio with the air flow rate through the valve88 for air supply. Block112 data processing/storage may be configured to generate a ratio of flow rate through the pump70 to supply the suspension to the flow rate through an air hose86 and to maintain the ratio of the flow rate of the slurry pump and the flow rate of the air hose when the flow rate of the air hose changes. The operator can stop the pump70 to supply the suspension by entering the “stop” command via the display102 controller HMI or via panel104 control, or manipulating the actuator90 valve for air supply; in certain device configurations the pump70 suspension supply is switched off when the air flow through the valve is blocked88 for air supply. In certain device configurations2 batch production and continuous application pump deactivation70 for supplying suspension and/or supplying air after system initialization blocks the start of the batch process in the mixer10 periodic action. Data provided by the sensor66contents of the product container can be accepted by the controller100and used by the block112processing/storing data to block the start of batch processing in the mixer10 periodic action or introducing the components of the composition into the mixer10 periodic action if a new batch cannot be placed in the container60 for the product.

[72] A process that uses the apparatus described herein for batch production and continuous application of a refractory composition to a surface may include the following steps:

[73] (a) providing the batch production and continuous application device 2 according to claim 1;

[74] (b) providing commands to the controller 100 ;

[75] (c) using the data processing/storage unit 112 , the powder material supply valve controller 40 and the powder material supply valve 38 , and data from the product container contents sensor 66 to control the movement of the powder material from the powder material hopper 30 to a batch reactor 10 for loading the batch reactor 10 ;

[76] (d) using the data processing/storage unit 112 , the batch reactor drive controller 18 , the batch reactor drive 16 , and data from the product container contents sensor 66 to activate, control, and deactivate the mixing assembly 17 in the batch reactor 10 for processing powdered material to form a product;

[77] (e) using data processing/storage unit 112 , batch reactor door actuator 24 and batch reactor door 22 , and data from product vessel contents sensor 66 to supply product from batch reactor 10 to product vessel 60 ;

[78] (f) moving the product from the product container 60 to the nozzle 80;

[79] (g) air supply to the nozzle 80 ;

[80] (h) combining the product with air inside the nozzle 80 ;

[81] (h) atomization of combined air and product; And

[82] (i) repeating steps (c), (d) and (e) to ensure continuous supply of product.

[83] Step (c) may further include (c') using data processing/storage unit 112 , water valve actuator 56 , water valve 54 , and data from product container contents sensor 66 to control the supply of water to batch reactor 10 .

[84] Step (c) may include the constraint that transfer of powdery material from the powdery material hopper 30 to the batch reactor 10 and supply of water to the batch reactor 10 are possible if the data processing/storage unit 112 determines that the batch reactor 10 is not loaded and that the product container 60 can accommodate the product to be produced from the powdered material and the water to be supplied to the batch reactor 10 , and that at least one of system initialization (in which the product is produced at the beginning) occurs work before spraying can begin) and spraying.

[85] Step (d) may include:

[86] activating the mixing unit 17 if the data processing/storage unit 122 determines that the slurry pump 70 is activated, that the batch reactor 10 is loaded, and that the product container 60 can accommodate the contents of the batch reactor 10 ;

[87] activating the mixing assembly 17 during system initialization if the batch reactor 10 is loaded and the product container 60 can accommodate the contents of the batch reactor 10 ;

[88] suspending operation of the mixing assembly 17 if the data processing/storage unit 122 determines that the slurry pump 70 is activated, that the batch reactor 10 is loaded, and that the product container 60 cannot accommodate the contents of the batch reactor 10 ;

[89] deactivating the mixing unit 17 if the data processing/storage unit 122 determines that batch processing is completed; And

[90] deactivating the mixing unit 17 if the data processing/storage unit 122 determines that the slurry pump 70 is deactivated.

[91] Data from the load measurement sensor 20 may be used to control the movement of powdered material from the powdered material hopper 30 to the batch reactor 10 to load the batch reactor 10 and to control the supply of water to the batch reactor 10 .

EXAMPLE

[92] The batch production and continuous application apparatus 2 is configured to produce, from a single mixture of components, refractory suspensions having a range of densities. Different densities are obtained by mixing components with specific values over ranges of time periods and mixing speeds. A calibration table, which shows slurry densities obtained for various combinations of mixing times, mixing speeds and spray pressures, allows the device to be programmed and commands entered to produce the formulation at the desired density.

Example 1 :

[93] The table below shows the results of experiments conducted to correlate batch reactor mixer speed and mixing time with densities as a function of density reduction. The base density of this composition using a conventional continuous mixer is approximately 120 lb/ft ³ (1920 kg/m ³ ). The mixture of dry components contained 93% refractory, 0.25% anionic surfactants and binders. A mixture of dry components was mixed with water to obtain a suspension containing 20 wt. % water. 200 lb (90 kg) batches of mixed dry ingredients were mixed intermittently for 7 minutes. Water was then added and the batches were mixed for the times and rates shown in TABLE I. The densities of the suspensions were obtained after removal from the batch mixer or after spraying as indicated in the table.

TABLE I. Mixing speed, mixing time, and atomizing pressure versus density Mixing speed (rpm) Mixing time (min) Density Sample 42 3 1540 kg/m ³
96.0 lb/ft ³ From the mixer 42 5 1450 kg/m ³
90.7 lb/ft ³ From the mixer 42 8 1370 kg/m ³
85.4 lb/ft ³ From the mixer 42 8 1530 kg/m ³
95.7 lb/ft ³ Sprayed 20 psi. inch (140 kPa) 42 8 1690 kg/m ³
105.5 lb/ft ³ Sprayed 30 psi. inch (210 kPa) 42 8 1740 kg/m ³
108.8 lb/ft ³ Sprayed 35 psi. inch (240 kPa) 42 8 1610 kg/m ³
100.4 lb/ft ³ Sprayed 15 psi. inch (103 kPa) 84 5 1310 kg/m ³
81.6 lb/ft ³ From the mixer 84 5 1790 kg/m ³
111.6 lb/ft ³ Sprayed 20 psi. inch (140 kPa) 84 5 1590 kg/m ³
99.5 lb/ft ³ Sprayed 10 psi. inch (69 kPa) 84 2.5 1560 kg/m ³
97.44 lb/ft ³ From the mixer 84 2.5 1700 kg/m ³
106.44 lb/ft ³ Sprayed 20 psi. inch (140 kPa) 84 2.5 1570 kg/m ³
97.8 lb/ft ³ Sprayed 10 psi. inch (69 kPa)

[94] Elements:

2. Batch production and continuous application device

10. Batch reactor

12. Batch reactor powder feed port

14. Batch reactor water supply inlet

16. Batch reactor drive

17. Mixing unit

18. Batch reactor drive regulator

20. Load measurement sensor

22. Batch reactor door

24. Batch reactor door actuator

30. Hopper for powdery material

32. Powder material hopper vibration device

34. Actuator mechanism of the vibration device of the hopper for powdery material

38. Valve for supplying powdery material

40. Powder material supply valve regulator

42. Powder material feeder

44. Powder material feeder regulator

50. Water supply device

52. Water flow speed sensor

54. Water valve

56. Water valve actuator

60. Product container

62. Vibration device for product container

64. Actuator of the vibrating device of the product container

66. Product container content sensor

68. Contents of product container

70. Suspension pump

72. Suspension pump regulator

76. Hose for supplying suspension

80. Nozzle

86. Air hose

88. Air supply valve

90. Valve actuator for air supply

92. Air flow sensor

100. Controller

101. Controller connections

102. Controller HMI display

104. Control panel

106. Command transmission port

108. Data collection port

112. Data processing/storage unit

ASPECTS OF THE INVENTION

[95] Various aspects of the present invention include, but are not limited to, the following numbered paragraphs.

[96] 1. Batch production and continuous application device 2 , comprising:

a powder material hopper 30 having an outlet;

a powder material supply valve 38 located at the outlet of the powder material hopper;

a powder material supply valve controller 40 in communication with the powder material supply valve 38 ;

a batch reactor 10 comprising an inlet 12 , a door 22, a batch reactor drive 16 , a mixing unit 17, a batch reactor drive regulator 18 , a door 22, and a batch reactor door actuator 24 ; wherein the outlet of the powder material hopper 30 communicates with the inlet 12 of the batch reactor; in this case, the regulator 18 of the drive of the periodic reactor communicates with the possibility of control with the drive 16 of the periodic reactor; in this case, the drive 16 of the batch reactor is mechanically connected to the mixing unit 17 ; and wherein the actuator 24 of the batch reactor door is in controllable communication with the door 22 ;

a product container 60 having an inlet and an outlet, the inlet of the product container 60 being configured to receive the contents of the batch reactor 10 passing through the door 22 ;

a product container contents sensor 66 in sensing communication with the amount of contents 68 of the product container 60 ;

a controller 100 containing a data processing/storage unit 112 ; wherein the data processing/storage unit 112 is in controllable communication with the sensor 66 of the contents of the product container, wherein the data processing/storage unit 112 is in controllable communication with the powder material supply valve controller 40 ; in this case, the data processing/storage unit 112 communicates with the possibility of control with the controller 18 of the drive of the periodic reactor; and wherein the data processing/storage unit 112 is in controllable communication with the batch reactor door actuator 24 ;

a nozzle 80 having an inlet and an outlet, the inlet of the nozzle receiving an outlet from the outlet of the product container 60 ; in this case, the inlet hole of the nozzle receives the outlet of the air hose 86 ; and wherein the air flow in the air hose 86 is controlled by the air supply valve 88 and is controlled by the air supply valve actuator 90 .

[97] 2. Batch production and continuous application device 2 according to claim 1, further comprising:

a powder material feeder 42 comprising an inlet and an outlet, wherein the outlet of the powder hopper 30 communicates with the inlet of the powder material feeder 42 , wherein the outlet of the powder material feeder 42 communicates with the inlet 14 of the batch reactor 10 ; And

a powder material feeder controller 44 , wherein the powder material feeder controller 44 is in controllable communication with the powder material feeder 42 ; and wherein the data processing/storage unit 112 is in controllable communication with the powder material feeder controller 44 .

[98] 3. Batch production and continuous application device 2 according to any of paragraphs 1 and 2, further comprising:

a slurry pump 70 having an inlet and an outlet, the inlet of the slurry pump 70 communicating with the outlet of the product container 60 ; in this case, the outlet of the pump 70 for supplying the suspension communicates with the inlet of the nozzle 80 ; And

pump controller 72 for supplying suspension; wherein the slurry pump controller 72 is in controllable communication with the slurry pump 70 ; wherein the data processing/storage unit 112 is in controllable communication with the slurry pump controller 72 .

[99] 4. Batch production and continuous application device 2 according to any of paragraphs 1-3, further comprising:

water valve 54 ;

a water supply device 50 , wherein the water supply device 50 extends through the water valve 54 to the water supply inlet 14 of the batch reactor of the batch reactor 10 ; And

water valve actuator 56 ; wherein the water valve actuator 56 is in controllable communication with the water valve 54 , and wherein the data processing/storage unit 112 is in controllable communication with the water valve actuator 56 .

[100] 5. Batch production and continuous application device 2 according to any one of paragraphs 1-4, further comprising:

a water flow rate sensor 52 is in sensing communication with the water supply device 50 , and a data processing/storage unit 112 is in receiving communication with the water flow rate sensor 52 .

[101] 6. The batch production and continuous application device 2 according to any one of items 1 to 5, characterized in that the data processing/storage unit 112 is configured to process data received from the product container contents sensor 66 to control the valve regulator 40 for supplying powdery material, the actuator 56 of the water valve and the regulator 18 of the drive of the batch reactor.

[102] 7. Batch production and continuous application device 2 according to any one of paragraphs 1-6, further comprising:

a load measuring sensor 20 is in sensing communication with the batch reactor 10 , and a data processing/storage unit 112 is in receiving communication with the load sensing sensor 20 .

[103] 8. Batch production and continuous application device 2 according to any one of paragraphs 1 to 7, further comprising:

a powder material hopper vibration device 32 communicating with the powder material hopper 30 ,

actuator 34 of the vibration device of the hopper for powdery material; wherein the actuator 34 of the powder material hopper vibration device is in controllable communication with the powder material hopper vibration device 32 ;

a product container vibrating device 62 in communication with the product container 60 , and

a product container vibration device actuator 64 , wherein the product container vibration device actuator 64 is in controllable communication with the product container vibration device 62 .

[104] 9. Batch production and continuous application device 2 according to any one of paragraphs 1 to 8, characterized in that:

the data processing/storage unit 112 is configured to generate a ratio of the flow rate through the slurry pump 70 to the flow rate through the air hose 86 and maintain a ratio of the flow rate of the slurry pump to the flow rate of the air hose when the flow rate of the air hose changes.

[105] 10. Batch production and continuous application device 2 according to any of claims 1 to 9, characterized in that:

The batch reactor drive 16 is configured to supply mechanical power of at least 7500 W to the mixing unit 17 .

[106] 11. A method of batch production and continuous application of a refractory composition, including:

providing a device 2 for batch production and continuous application according to claim 1;

providing commands to the controller 100 ;

using the data processing/storage unit 112 , the powder material supply valve controller 40 and the powder material supply valve 38 , and data from the product container contents sensor 66 to control the movement of the powder material from the powder material hopper 30 to the batch reactor 10 for loading batch reactor 10 ;

using data processing/storage unit 112 , batch reactor drive controller 18 , batch reactor drive 16 , and data from product container contents sensor 66 to activate, control, and deactivate mixing assembly 17 in batch reactor 10 to process powdered material to form product ;

using the data processing/storage unit 112 , the batch reactor door actuator 24 and the batch reactor door 22 , and data from the product container contents sensor 66 to supply product from the batch reactor 10 to the product container 60 ;

moving the product from the product container 60 to the nozzle 80;

air supply to the nozzle 80 ;

combining the product with air inside the nozzle 80 ;

atomization of combined air and product; And

repeating steps (c), (d) and (e) to ensure a continuous supply of product.

[107] 12. The method of batch production and continuous application of refractory composition according to claim 11, characterized in that the batch production and continuous application device 2 further comprises a water supply device 50 , a water valve 54 and a water valve actuator 56 , wherein the reactor 10 the batch reactor further comprises an inlet 14 for supplying water to the batch reactor; wherein the water supply device 50 passes through the water valve 54 to the water supply inlet 14 of the batch reactor; wherein the water valve actuator 56 is in controllable communication with the water valve 54 , and wherein the data processing/storage unit 112 is in controllable communication with the water valve actuator 56 ; and wherein step (c) further includes:

(c') using the data processing/storage unit 112 , the water valve actuator 56 , the water valve 54 , and data from the product container contents sensor 66 to control the supply of water to the batch reactor 10 .

[108] 13. The method for batch production and continuous application of a refractory composition according to any one of items 11-12, characterized in that transferring powdery material from the powdery material hopper 30 to the batch reactor 10 and supplying water to the batch reactor 10 are possible if the data processing/storage unit 112 determines that the batch reactor 10 is not loaded and that the product container 60 can accommodate the product to be produced from the powdered material and the water to be supplied to the batch reactor 10 , and that at least one of system initialization and spraying.

[109] 14. The batch production and continuous application method of a refractory composition according to any one of items 11 to 13, characterized in that the batch production and continuous application device 2 further comprises a slurry supply pump 70 having an inlet port and an outlet port; in this case, device 2 additionally contains a pump regulator 72 for supplying the suspension; wherein the inlet of the suspension pump 70 communicates with the outlet of the product container 60 ; in this case, the outlet of the pump 70 for supplying the suspension communicates with the inlet of the nozzle 80 ; and wherein the slurry pump controller 72 is in controllable communication with the slurry pump 70 ; wherein the data processing/storage unit 112 is in controllable communication with the suspension pump controller 72 ; and wherein step (d) includes:

activating the mixing unit 17 if the data processing/storage unit 122 determines that the slurry pump 70 is activated, that the batch reactor 10 is loaded, and that the product container 60 can accommodate the contents of the batch reactor 10 ;

activating the mixing unit 17 during system initialization if the batch reactor 10 is loaded and the product container 60 can accommodate the contents of the batch reactor 10 ;

suspending operation of the mixing assembly 17 if the data processing/storage unit 122 determines that the slurry pump 70 is activated, that the batch reactor 10 is loaded, and that the product container 60 cannot accommodate the contents of the batch reactor 10 ;

deactivating the mixing unit 17 if the data processing/storage unit 122 determines that batch processing is complete;

deactivating the mixing unit 17 if the data processing/storage unit 122 determines that the slurry pump 70 is deactivated.

[110] 15. The method of batch production and continuous application of a refractory composition according to claim 12, characterized in that the batch production and continuous application device 2 further comprises a load measurement sensor 20 , which communicates with the possibility of measurement with the batch reactor 10 , wherein the unit 112 data processing/storage communicates with the ability to receive load measurement sensor 20 ; And

wherein data from the load sensing sensor 20 is used to control the movement of powdery material from the powdery material hopper 30 to the batch reactor 10 to load the batch reactor 10 and to control the supply of water to the batch reactor 10 .

[111] The present invention may include, consist of, or be substantially composed of various features and characteristics described herein. In some cases, the invention may also be substantially free of a component or other feature or characteristic described herein.

[112] In addition, any numeric range specified herein includes the specified endpoints and describes all subranges with the same numerical precision ( i.e., having the same number of specified digits) included in the specified range. For example, the specified range "1.0 to 10.0" describes all subranges between (and including) the specified minimum value of 1.0 and the specified maximum value of 10.0, such as "2.4 to 7.6", even unless the range "2.4 to 7.6" is explicitly stated in the text of this description. Accordingly, Applicant reserves the right to amend this specification, including the claims, to explicitly indicate any sub-range with the same numerical precision included in the ranges expressly set forth in this specification. All such ranges are substantially set forth herein in such a manner that modification to expressly indicate any such subranges will satisfy the requirements of the written description, sufficiency of the description, and additional materials ( for example , 35 USC § 112(a) and EPC 123(2) ).

[113] The singular forms used herein include “at least one” or “one or more” unless otherwise indicated or required by the context. Singular forms are used herein to denote one or more than one ( ie, "at least one") of the grammatical entities. For example, “component” means one or more components, and thus, perhaps more than one component is contemplated and may be involved or used in implementing the present invention. In addition, the use of a singular noun includes plural forms, and the use of a plural noun includes singular forms unless the context of use requires otherwise.

Claims (54)

1. Device (2) for batch production and continuous application of refractory composition, containing: a hopper (30) for powdery material having an outlet; a powder material supply valve (38) located in the outlet of the powder material hopper; a powder material supply valve regulator (40) in controllable communication with the powder material supply valve (38); a batch reactor (10) containing an inlet (12), a door (22), a batch reactor drive (16), a mixing unit (17), a batch reactor drive regulator (18), a door (22) and an actuator ( 24) batch reactor doors; wherein the outlet of the hopper (30) for powdery material communicates with the inlet (12) of the batch reactor; in this case, the regulator (18) of the drive of the periodic reactor communicates with the possibility of control with the drive (16) of the periodic reactor; in this case, the drive (16) of the batch reactor is mechanically connected to the mixing unit (17); and wherein the actuator (24) of the batch reactor door is in controllable communication with the door (22); a product container (60) having an inlet and an outlet, the inlet of the product container (60) being configured to receive the contents of the batch reactor (10) passing through the door (22); a product container contents sensor (66) in sensing communication with the amount of contents (68) of the product container (60); controller (100) containing a data processing/storage unit (112); wherein the data processing/storage unit (112) is in controllable communication with the sensor (66) of the contents of the product container, wherein the data processing/storage unit (112) is in controllable communication with the powder material supply valve regulator (40); in this case, the data processing/storage unit (112) communicates with the possibility of control with the controller (18) of the drive of the periodic reactor; and wherein the data processing/storage unit (112) is in controllable communication with the batch reactor door actuator (24); a nozzle (80) having an inlet and an outlet, the inlet of the nozzle receiving an outlet from the outlet of the product container (60); wherein the inlet of the nozzle receives the outlet of the air hose (86); and wherein the air flow in the air hose (86) is controlled by the air supply valve (88) and is controlled by the air supply valve actuator (90); water valve (54); a water supply device (50), wherein the water supply device (50) passes through the water valve (54) to the water supply inlet (14) of the batch reactor of the batch reactor (10); And water valve actuator (56); wherein the water valve actuator (56) is in controllable communication with the water valve (54), and wherein the data processing/storage unit (112) is in controllable communication with the water valve actuator (56). 2. Device (2) for batch production and continuous application according to claim 1, further comprising: a powder material feeder (42) comprising an inlet and an outlet, wherein the outlet of the powder material hopper (30) communicates with the inlet of the powder material feeder (42), wherein the outlet of the powder material feeder (42) communicates with the inlet (14) batch reactor (10); And regulator (44) of the powder material feeder, wherein the regulator (44) of the powder material feeder is in controllable communication with the powder material feeder (42); and wherein the data processing/storage unit (112) is in controllable communication with the powder material feeder controller (44). 3. Batch production and continuous application device (2) according to any of the preceding claims, further comprising: a slurry pump (70) comprising an inlet and an outlet, the inlet of the slurry pump (70) communicating with the outlet of the product container (60); wherein the outlet of the pump (70) for supplying the suspension communicates with the inlet of the nozzle (80); And regulator (72) of the pump for supplying the suspension; wherein the regulator (72) of the pump for supplying the suspension is in controllable communication with the pump (70) for supplying the suspension; wherein the data processing/storage unit (112) is in controllable communication with the pump controller (72) for supplying the suspension. 4. Device (2) for batch production and continuous application according to claim 3, characterized in that the data processing/storage unit (112) is configured to generate a ratio of the flow rate through the slurry pump (70) and the flow rate through the air hose (86) and maintain the ratio of the flow rate of the slurry pump and the flow rate of the air hose when the flow rate changes air hose. 5. Device (2) for batch production and continuous application according to claim 4, further comprising a water flow rate sensor (52) that communicates with the possibility of measurement with a water supply device (50), while the data processing/storage unit (112) communicates with the possibility of receiving the water flow rate sensor (52). 6. Device (2) for batch production and continuous application according to claim 4 or 5, characterized in that the data processing/storage unit (112) is configured to process data received from the sensor (66) of the contents of the product container to control the regulator (40) valve for supplying powdery material, actuator (56) of the water valve and regulator (18) of the drive of the batch reactor. 7. Batch production and continuous application device (2) according to any of the preceding claims, further comprising a load measurement sensor (20) communicates with the possibility of measurement with a periodic reactor (10), while the data processing/storage unit (112) communicates with the possibility of reception with the load measurement sensor (20). 8. Batch production and continuous application device (2) according to any of the preceding claims, further comprising: vibration device (32) of the hopper for powdery material, communicating with the hopper (30) for powdery material, actuator (34) of the vibration device of the hopper for powdery material; wherein the actuator (34) of the vibration device of the hopper for powdery material communicates with the possibility of control with the vibration device (32) of the hopper for powdery material; a product container vibration device (62) communicating with the product container (60); And an actuator (64) of the product container vibrating device, wherein the actuator (64) of the product container vibration device is in controllable communication with the product container vibration device (62). 9. Batch production and continuous application device (2) according to any of the preceding claims, characterized in that the drive (16) of the batch reactor is configured to supply at least 7500 W of mechanical power to the mixing unit (17). 10. A method of batch production and continuous application of a refractory composition, including: (a) providing a device (2) for batch production and continuous application according to any one of paragraphs. 1-9; (b) providing commands to the controller (100); (c) using a data processing/storage unit (112), a powder material supply valve controller (40), and a powder material supply valve (38) and data from a product container contents sensor (66) to control the movement of powder material from the hopper ( 30) for powdered material into the batch reactor (10) to load the batch reactor (10); (d) using the data processing/storage unit (112), the batch reactor drive controller (18), the batch reactor drive (16) and data from the product container contents sensor (66) to activate, control and deactivate the mixing unit (17 ) in a batch reactor (10) for processing powdered material to form a product; (e) using the data processing/storage unit (112), the batch reactor door actuator (24), and the batch reactor door (22), and data from the product container contents sensor (66) to feed product from the batch reactor (10) actions into the container (60) for the product; (f) moving the product from the product container (60) to the nozzle (80); (g) supplying air to the nozzle (80); (h) combining the product with air inside the nozzle (80); (i) atomizing the combined air and product; And (j) repeating steps (c), (d) and (e) to ensure continuous supply of product; And wherein the batch production and continuous application device (2) additionally contains a water supply device (50), a water valve (54) and a water valve actuator (56), while the batch reactor (10) additionally contains an inlet (14) for batch reactor water supply; wherein the water supply device (50) passes through the water valve (54) to the water supply inlet (14) of the batch reactor; wherein the water valve actuator (56) is in controllable communication with the water valve (54), and wherein the data processing/storage unit (112) is in controllable communication with the water valve actuator (56); and wherein step (c) further includes: (c') using a data processing/storage unit (112), a water valve actuator (56), a water valve (54) and data from a product container contents sensor (66) to control the supply of water to the batch reactor (10). 11. The method of batch production and continuous application of refractory composition according to claim 10, characterized in that the movement of powdered material from the hopper (30) for powdered material into the batch reactor (10) and the supply of water to the batch reactor (10) are possible if the data processing/storage unit (112) determines that the batch reactor (10) is not loaded and that the product container (60) can accommodate the product to be produced from the powdered material and water to be supplied to the batch reactor (10), and that at least one of system initialization and spraying occurs. 12. Method of batch production and continuous application of refractory composition according to any one of paragraphs. 10 and 11, characterized in that the batch production and continuous application device (2) further comprises a suspension pump (70) having an inlet and an outlet; in this case, the device (2) additionally contains a pump regulator (72) for supplying the suspension; wherein the inlet of the pump (70) for supplying the suspension communicates with the outlet of the container (60) for the product; wherein the outlet (70) of the pump for supplying the suspension communicates with the inlet of the nozzle (80); and wherein the slurry pump controller (72) is in controllable communication with the slurry pump (70); wherein the data processing/storage unit (112) is in controllable communication with the pump controller (72) for supplying the suspension; and wherein step (d) includes: activation of the mixing unit (17) if the data processing/storage unit (112) determines that the slurry pump (70) is activated, that the batch reactor (10) is loaded and that the product container (60) can accommodate the contents of the reactor (10 ) periodic action; activating the mixing unit (17) during system initialization if the batch reactor (10) is loaded and the product container (60) can accommodate the contents of the batch reactor (10); suspending the operation of the mixing unit (17) if the data processing/storage unit (112) determines that the slurry pump (70) is activated, that the batch reactor (10) is loaded and that the product container (60) cannot contain the contents of the reactor (10) periodic action; deactivating the mixing unit (17) if the data processing/storage unit (112) determines that batch processing is completed; deactivation of the mixing unit (17) if the data processing/storage unit (112) determines that the suspension pump (70) is deactivated. 13. Method of batch production and continuous application of refractory composition according to any one of paragraphs. 10, 11 and 12, characterized in that the device (2) for batch production and continuous application additionally contains a load measurement sensor (20), which communicates with the possibility of measurement with the batch reactor (10), while the data processing/storage unit (112) communicates with the possibility of receiving a load measurement sensor (20); And wherein data from the load measurement sensor (20) is used to control the movement of powdery material from the powdery material hopper (30) into the batch reactor (10) to load the batch reactor (10) and to control the supply of water to the batch reactor (10). .