Zircon-based sintered concrete

Patent metadata

Field	Value
Publication number	US-11059752-B2
Application number	US-201716467729-A
Country	US
Kind code	B2
Filing date	Dec 13, 2017
Priority date	Dec 14, 2016
Publication date	Jul 13, 2021
Grant date	Jul 13, 2021

Abstract

A sintered concrete having the following mean chemical composition, as mass percentages on the basis of the oxides and for a total of 100%; ZrO 2 : 55 to 70%, SiO 2 : 25 to 40%, P 2 O 5 : 0.2 to 9.0%, Al 2 O 3 : 0.5 to 7.0%, CaO: >0.2%, CaO+MgO+B 2 O 3 +Fe 2 O 3 : 0.2 to 10.0%, MgO+B 2 O 3 +Fe 2 O 3 ; ≤7.5%, B 2 O 3 +MgO: ≤4.5%, ZrO 2 +SiO 2 +P 2 O 5 +Al 2 O 3 +CaO+MgO+B 2 O 3 +Fe 2 O 3 : ≥95.0%, and containing more than 70% of zircon, as a mass percentage on the basis of the mass of the crystalline phases.

First claim

The invention claimed is:

1. A sintered concrete having the following chemical composition, as mass percentages on the basis of the oxides and for a total of 100%:
ZrO 2 : 55 to 70%,
SiO 2 : 25 to 40%,
P 2 O 5 : 0.2 to 9.0%,
Al 2 O 3 : 0.5 to 7.0%,
CaO: >0.2%,
CaO+MgO+B 2 O 3 +Fe 2 O 3 : 0.2 to 10.0%,
MgO+B 2 O 3 +Fe 2 O 3 : ≤7.5%,
B 2 O 3 +MgO: ≤4.5%,
ZrO 2 +SiO 2 +P 2 O 5 +Al 2 O 3 +CaO+MgO+B 2 O 3 +Fe 2 O 3 : ≥95.0%, said sintered concrete having crystalline phases and containing more than 70% of zircon, as a mass percentage on the basis of the mass of the crystalline phases, the oxides representing more than 98.5% of the mass of the sintered concrete.

2. The sintered concrete as claimed in claim 1 , said composition being such that:
the content of ZrO 2 is greater than 57% and less than 67%; and/or
the content of SiO 2 is greater than 26% and less than 37%; and/or
the content of P 2 O 5 is greater than 0.3% and less than 8.5%; and/or
the sum of the contents of CaO, MgO, B 2 O 3 and Fe 2 O 3 is greater than 0.3% and less than 9.5%; and/or
the content of CaO is greater than 0.3% and less than 7.9%; and/or
the sum of the contents of MgO, B 2 O 3 and Fe 2 O 3 is less than 7.0%; and/or
the sum of the contents of MgO and B 2 O 3 is less than 4%; and/or
the sum of the contents of oxides other than ZrO 2 , SiO 2 , P 2 O 5 , Al 2 O 3 , CaO, MgO, B 2 O 3 and Fe 2 O 3 is less than 4.5%.

3. The sintered concrete as claimed in claim 1 , said composition being such that:
the content of ZrO 2 is greater than 58% and less than 65%; and/or
the content of SiO 2 is greater than 27% and less than 35%; and/or
the content of P 2 O 5 is greater than 0.7% and less than 5.0%; and/or
the sum of the contents of CaO, MgO, B 2 O 3 and Fe 2 O 3 is greater than 0.5% and less than 5.9%; and/or
the content of CaO is greater than 0.4% and less than 5.0%; and/or
the sum of the contents of MgO, B 2 O 3 and Fe 2 O 3 is less than 3.5%; and/or
the sum of the contents of MgO and B 2 O 3 is less than 2.4%; and/or
the sum of the contents of oxides other than ZrO 2 , SiO 2 , P 2 O 5 , Al 2 O 3 , CaO, MgO, B 2 O 3 and Fe 2 O 3 is less than 3.0%.

4. The sintered concrete as claimed in claim 1 , in which the content of zircon, as a mass percentage on the basis of the crystalline phases, is greater than 80%.

5. The sintered concrete as claimed in claim 1 , which is in the form of a block, all the dimensions of which are greater than 1 mm.

6. The sintered concrete as claimed in claim 1 , having the following chemical composition, as mass percentages on the basis of the oxides and for a total of 100%:
ZrO 2 : 55 to 70%,
SiO 2 : 25 to 40%,
CaO: 0.2 to 3.0%,
Al 2 O 3 : 0.5 to 7.0%,
MgO: 0.1 to 3.0%,
P 2 O 5 : 0.3 to 9.0%,
other oxides: <5.0%.

7. The sintered concrete as claimed in claim 6 , said composition being such that:
ZrO 2 >59%, and/or
SiO 2 >27%, and/or
CaO>0.4%, and/or
Al 2 O 3 >1.0%, and/or
MgO>0.3%, and/or
P 2 O 5 >0.7%.

8. The sintered concrete as claimed in claim 7 , said composition being such that:
ZrO 2 >61%, and/or
SiO 2 >29%, and/or
CaO>0.5%, and/or
Al 2 O 3 >1.5%, and/or
MgO>0.4%, and/or
P 2 O 5 >1.2%.

9. The sintered concrete as claimed in claim 1 , said composition being such that:
ZrO 2 <67%, and/or
SiO 2 <35%, and/or
CaO<2.0%, and/or
Al 2 O 3 <6.0%, and/or
MgO<2.1%, and/or
P 2 O 5 <5.0%, and/or
other oxides <3.5%.

10. The sintered concrete as claimed in claim 9 , said composition being such that:
ZrO 2 <65%, and/or
SiO 2 <31%, and/or
CaO<1.2%, and/or
Al 2 O 3 <4.0%, and/or
MgO<0.9%, and/or
P 2 O 5 <3.0%, and/or
other oxides <2%.

11. The sintered concrete as claimed in claim 1 , in which:
the content of P 2 O 5 is greater than 0.3% and less than 5.8%, and
the content of Fe 2 O 3 is greater than 0.1% and less than 6.5%, and
the content of MgO is less than 0.5%, and
the content of B 2 O 3 is less than 0.5%, and
the content of CaO is greater than 0.3% and less than 3%, and
the sum of the contents of MgO and B 2 O 3 is less than 1%, and
the sum of the contents of CaO, MgO, B 2 O 3 and Fe 2 O 3 is greater than 0.3% and less than 10%, and
the sum of the contents of MgO, B 2 O 3 and Fe 2 O 3 is greater than 0.1% and less than 7.0%.

12. The sintered concrete as claimed in claim 11 , in which:
the content of P 2 O 5 is greater than 0.5% and less than 3.0%, and/or
the content of Fe 2 O 3 is greater than 0.5% and less than 3.5%, and/or
the content of MgO is less than 0.3%, and/or
the content of B 2 O 3 is less than 0.3%, and/or
the content of CaO is greater than 0.4% and less than 2.0%, and/or
the sum of the contents of MgO and B 2 O 3 is less than 0.6%, and/or
the sum of the contents of CaO, MgO, B 2 O 3 and Fe 2 O 3 is greater than 0.7% and less than 5.1%, and/or
the sum of the contents of MgO, B 2 O 3 and Fe 2 O 3 is greater than 0.5% and less than 4.4%.

13. The sintered concrete as claimed in claim 1 , in which:
the content of P 2 O 5 is greater than 0.25% and less than 8.3%, and
the content of B 2 O 3 is greater than 0.05% and less than 4.0%, and
the content of MgO is less than 0.5%, and
the content of Fe 2 O 3 is less than 0.5%, and
the content of CaO is greater than 0.3% and less than 3%, and
the sum of the contents of CaO, MgO, B 2 O 3 and Fe 2 O 3 is greater than 0.3% and less than 8.0%, and
the sum of the contents of MgO, B 2 O 3 and Fe 2 O 3 is greater than 0.05% and less than 5.0%, and
the sum of the contents of MgO and B 2 O 3 is greater than 0.05% and less than 4.5%.

14. The sintered concrete as claimed in claim 13 , in which:
the content of P 2 O 5 is greater than 0.7% and less than 4.5%, and/or
the content of B 2 O 3 is greater than 0.2% and less than 2.0%, and/or
the content of MgO is less than 0.3%, and/or
the content of Fe 2 O 3 is less than 0.3%, and/or
the content of CaO is greater than 0.4% and less than 1.5%, and/or
the sum of the contents of CaO, MgO, B 2 O 3 and Fe 2 O 3 is greater than 0.5% and less than 4.2%, and/or
the sum of the contents of MgO, B 2 O 3 and Fe 2 O 3 is greater than 0.2% and less than 3.0%, and/or
the sum of the contents of MgO and B 2 O 3 is greater than 0.2% and less than 3.0%.

15. The sintered concrete as claimed in claim 1 , in which:
the content of P 2 O 5 is greater than 0.25% and less than 7.0%, and
the content of CaO is greater than 0.3% and less than 8.4%, and
the content of B 2 O 3 is less than 0.5%, and
the content of MgO is less than 0.5%, and
the content of Fe 2 O 3 is less than 0.5%, and
the sum of the contents of CaO, MgO, B 2 O 3 and Fe 2 O 3 is greater than 0.3% and less than 9.5%, and
the sum of the contents of MgO, B 2 O 3 and Fe 2 O 3 is less than 1.5%, and
the sum of the contents of MgO and B 2 O 3 is less than 1.0%.

16. The sintered concrete as claimed in claim 15 , in which:
the content of P 2 O 5 is greater than 0.4% and less than 3.5%, and/or
the content of CaO is greater than 0.8% and less than 5.0%, and/or
the content of B 2 O 3 is less than 0.3%, and/or
the content of MgO is less than 0.3%, and/or
the content of Fe 2 O 3 is less than 0.3%, and/or
the sum of the contents of CaO, MgO, B 2 O 3 and Fe 2 O 3 is greater than 0.7% and less than 4.5%, and/or
the sum of the contents of MgO, B 2 O 3 and Fe 2 O 3 is less than 0.5%, and/or
the sum of the contents of MgO and B 2 O 3 is less than 0.5%.

17. The sintered concrete as claimed in claim 1 , in which:
the content of P 2 O 5 is great

Assignees

• Saint Gobain Ct Recherches

Inventors

• Champion Thibault
• Bobo Michel

Classifications

• C04B2235/447

  Phosphates or phosphites, e.g. orthophosphate or hypophosphite · CPC title

• C04B2235/3217

  Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina · CPC title

• C04B2235/5427

  millimeter or submillimeter sized, i.e. larger than 0,1 mm · CPC title

• C04B2235/42

  Non metallic elements added as constituents or additives, e.g. sulfur, phosphor, selenium or tellurium · CPC title

• C03B17/04

  Forming tubes or rods by drawing from stationary or rotating tools or from forming nozzles · CPC title