Unshaped product for repairing glass melting furnaces

Patent metadata

Field	Value
Publication number	US-11111183-B2
Application number	US-201615556438-A
Country	US
Kind code	B2
Filing date	Mar 7, 2016
Priority date	Mar 9, 2015
Publication date	Sep 7, 2021
Grant date	Sep 7, 2021

Abstract

An unshaped product including, as weight percentages, A) particles (a) of at least one refractory material other than a glass and a glass-ceramic, and the main constituent(s) of which are alumina and/or zirconia and/or silica and/or chromium oxide: B) 2% to 15% of particles (b) of a hot binder chosen from glass-ceramic particles, particles made of a glass, and the mixtures of these particles, a glass being a noncrystalline material exhibiting a glass transition temperature of less than 1100° C., the hot binder not being in the solid state at 1500° C., C) less than 2% of particles (c) of hydraulic cement, D) less than 7% of other constituents, the particles (a) and (b) being distributed, as weight percentages in the following way: fraction<0.5 μm: ≥1%, fraction<2 μm: ≥4%, fraction<10 μm: ≥13%, fraction<40 μm: 25%-52%.

First claim

The invention claimed is:

1. A wet mixture consisting of:
an unshaped product comprising, as percentages by weight and for a total of 100%,
A) a set of particles (a) of at least one refractory material other than a glass and a glass-ceramic, and the main constituent(s) of which are alumina (Al 2 O 3 ) and/or zirconia (ZrO 2 ) and/or silica (SiO 2 ) and/or chromium oxide (Cr 2 O 3 ),
B) a set of particles (b) of a hot binder chosen from glass-ceramic particles, particles made of a glass and the mixtures of these particles: 2% to 15%, said glass being a noncrystalline material exhibiting a glass transition temperature of less than 800° C., the hot binder not being in the solid state at 1500° C.,
C) a set of particles (c) of hydraulic cement: less than 2%,
D) less than 7% of constituents other than particles (a), (b), and (c), said particles (a) and (b) being distributed, as percentages by weight with respect to the weight of the unshaped product, in the following way:
fraction<0.5 μm: ≥1%,
fraction<2 μm: ≥4%,
fraction<10 μm: ≥13%,
fraction<40 μm: 25%-52%,

the content of the set of particles (a) being the complement, to reach 100%, to the whole content of the particles (b), of the set of particles (c) and of said other constituents, and
water in an amount of greater than 9%, by weight, with respect to the weight of said unshaped product.

2. The wet mixture as claimed in claim 1 , wherein the amount by weight of glass-ceramic particles in the set of particles (b) is greater than 10%, on the basis of the weight of the set of particles (b), and/or, wherein said set of particles (b) comprises particles made of said glass which are particles of a glass-ceramic precursor glass, and the amount by weight of said particles of glass-ceramic precursor glass in the set of particles (b) is greater than 10%, on the basis of the weight of the set of particles (b).

3. The wet mixture as claimed in claim 1 , in which the amount by weight of glass-ceramic particles in the set of particles (b) is greater than 95%, on the basis of the weight of the set of particles (b), and/or in which said set of particles (b) comprises particles made of said glass which are particles of a glass-ceramic precursor glass, and the amount by weight of said particles of glass-ceramic precursor glass in the set of particles (b) is greater than 95%, on the basis of the weight of the set of particles (b).

4. The wet mixture as claimed in claim 1 , in which the amount of hydraulic cement is less than or equal to 1%.

5. The wet mixture as claimed in claim 4 , in which the amount of hydraulic cement is substantially zero.

6. The wet mixture as claimed in claim 1 , in which the particles of the unshaped product are distributed in the following way, as percentages by weight:
fraction<0.5 m: ≤7% and/or
fraction<2 μm: ≥5% and/or
fraction<10 μm: ≥16% and/or
fraction<40 μm: ≥27% and/or
fraction of between 2 μm and 40 μm: ≥16% and/or ≤40%.

7. The wet mixture as claimed in claim 1 , in which the particles of the unshaped product are distributed in the following way, as percentages by weight:
fraction<0.5 μm: ≤6% and/or
fraction<2 μm: ≤18% and/or
fraction<10 μm: ≤40% and/or
fraction<40 μm: ≥29%.

8. The wet mixture as claimed in claim 1 , in which the particles of the unshaped product are distributed in the following way, as percentages by weight:
fraction<2 μm: ≤14% and/or
fraction<10 μm: ≤35% and/or
fraction<40 μm: ≤50%.

9. The wet mixture as claimed in claim 1 , in which the particles of the unshaped product are distributed in the following way, as percentages by weight:
fraction<2 μm: ≤12% and/or
fraction<10 μm: ≤30% and/or
fraction<40 μm: ≤42%.

10. The wet mixture as claimed in claim 1 , in which the maximum size of the particles of the unshaped product is less than or equal to 2.5 mm.

11. The wet mixture as claimed in claim 1 , in which the maximum size of the particles of the unshaped product is less than or equal to 2 mm.

12. The wet mixture as claimed in claim 1 , in which the amount of particles (a) is greater than 82% and/or less than 98% of the weight of the unshaped product.

13. The wet mixture as claimed in claim 1 , in which the amount of particles (b) is greater than 2% and less than 13% of the weight of the unshaped product.

14. The wet mixture as claimed in the claim 13 , in which the amount of particles (b) is greater than 3% and less than 12% of the weight of the unshaped product.

15. The wet mixture as claimed in claim 1 , in which the particles (b) exhibit a melting point of greater than 750° C. and of less than 1650° C.

16. The wet mixture as claimed in claim 1 , in which the particles (b) consist of a glass having a chemical composition, said chemical composition comprising, as percentage by weight, more than 90% of oxides.

17. The wet mixture as claimed in claim 1 , in which the particles (b) consist of a glass having a chemical composition, said chemical composition comprising, as percentage by weight, more than 45% and less than 80% of silica.

18. The wet mixture as claimed in claim 1 , in which the particles (b) made of a glass-ceramic precursor glass and/or the particles (b) made of glass-ceramic exhibit the following chemical composition, as percentages by weight on the basis of the oxides and for a total of more than 95%:
SiO 2 : 45-75%, and
Al 2 O 3 : 5-40%, and
CaO+MgO+Li 2 O: 3-30%,
nucleating agents, expressed in an oxide form: 0.1-20%.

19. The wet mixture as claimed in claim 18 , in which the amount by weight of the nucleating agents is greater than 1% and less than 10%.

20. The wet mixture as claimed in claim 18 , in which said nucleating agents are chosen from TiO 2 , ZrO 2 , P 2 O 5 and their mixtures.

21. The wet mixture as claimed in claim 1 , in which the particles (b) are distributed in the following way, as percentages by weight on the basis of the particles (b):
fraction<1 mm: ≥80%, and/or
fraction<0.5 mm: ≥80%, and/or
fraction<0.1 mm: ≥25% and/or
fraction<0.04 mm: ≤30%.

22. The wet mixture as claimed in claim 1 , in which the unshaped product exhibits a chemical composition such that, in percentages by weight, the sum Al 2 O 3 +ZrO 2 +SiO 2 +Cr 2 O 3 ≥85%.

23. The wet mixture as claimed in the claim 22 , in which the unshaped product exhibits a chemical composition such that, in percentages by weight, the sum Al 2 O 3 +ZrO 2 +SiO 2 ≥85%.

24. The wet mixture as claimed in claim 1 , in which the unshaped product exhibits a following composition, in percentages by weight, for a total of more than 95%:
Al 2 O 3 : 85%-97%,
SiO 2 : ≥1% and ≤11%.

25. The wet mixture as claimed in claim 1 , in which the unshaped product exhibits a composition, in percentages by weight such that:
Al 2 O 3 : 43%-60%,
ZrO 2 : 20%-43%,
SiO 2 : 10%-26%.

26. The wet mixture as claimed in claim 1 , in which the unshaped product exhibits a composition, in percentages by weight such that:
Al 2 O 3 : 5%-60%,
ZrO 2 : ≤35%,
SiO 2 : 5%-25%,
Cr 2 O 3 : 10%-90%.

27. The wet mixture as claimed in claim 1 , in which the unshaped product comprises a surface-active agent in an amount of between 0.075% and 1% of the weight of said unshaped product.

28. The wet mixture as claimed in claim 1 , in which the fraction of the particles with a size of less than 500 μm represents more than 50% of the weight of said unshaped product.

Assignees

• Saint Gobain Ct Recherches

Inventors

• Cabodi Isabelle
• Consales Thierry
• Gaubil Michel

Classifications

• C04B35/482 Primary

  Refractories from grain sized mixtures · CPC title

• C04B2235/3201

  Alkali metal oxides or oxide-forming salts thereof · CPC title

• C04B35/634

  Polymers (C04B35/636 takes precedence) · CPC title

• C04B35/66

  Monolithic refractories or refractory mortars, including those whether or not containing clay {(making or repairing of linings F27D1/16)} · CPC title

• F27D1/10

  Monolithic linings; Supports therefor · CPC title