Grains for the production of a sintered refractory product, a batch for the production of a sintered refractory product, a process for the production of a sintered refractory product and a sintered refractory product

Patent metadata

Field	Value
Publication number	US-11384021-B2
Application number	US-202016795910-A
Country	US
Kind code	B2
Filing date	Feb 20, 2020
Priority date	Feb 20, 2020
Publication date	Jul 12, 2022
Grant date	Jul 12, 2022

Abstract

Grains for the production of a sintered refractory product, a batch for the production of a sintered refractory product, a process for the production of a sintered refractory product and a sintered refractory product.

First claim

What is claimed is:

1. Grains for the production of a sintered refractory product, the grains for the production of the sintered refractory product comprising the following features:
1.1 the grains for the production of the sintered refractory product are made of at least one of the following grains:
1.1.1 grains made of magnesia, the surface of which have a coating of zirconia at least in sections; or
1.1.2 grains made of magnesite, the surface of which have a coating of zirconia at least in sections; or
1.1.3 grains made of doloma, the surface of which have a coating of zirconia at least in sections; or
1.1.4 grains made of dolomite, the surface of which have a coating of zirconia at least in sections;

1.2 the grains for the production of the sintered refractory product have a grain size of at least 2.8 mm;
1.3 wherein the proportion by weight of the coating of zirconia, in relation to the total weight of the grains for the production of the sintered refractory product, is in the range from 1 to 50% by weight.

2. The grains for the production of the sintered refractory product according to claim 1 , wherein the grains for the production of the sintered refractory product have a grain size in the range from 2.8 to 8.0 mm.

3. The grains for the production of the sintered refractory product according to claim 1 , wherein the coating of zirconia has a thickness of at least 10 μm.

4. The grains for the production of the sintered refractory product according to claim 1 , wherein the coating of zirconia has a thickness in the range from 10 to 800 μm.

5. A batch for the production of a sintered refractory product, the batch comprising grains for the production of the sintered refractory product, the grains for the production of the sintered refractory product comprising the following features:
6.1 the grains for the production of the sintered refractory product are made of at least one of the following grains:
6.1.1 grains made of magnesia, the surface of which have a coating of zirconia at least in sections; or
6.1.2 grains made of magnesite, the surface of which have a coating of zirconia at least in sections; or
6.1.3 grains made of doloma, the surface of which have a coating of zirconia at least in sections; or
6.1.4 grains made of dolomite, the surface of which have a coating of zirconia at least in sections;

6.2 the grains for the production of the sintered refractory product, comprised by the batch, have a grain size of at least 2.8 mm;
6.3 wherein the proportion by weight of the coating of zirconia, in relation to the total weight of the grains for the production of the sintered refractory product comprised by the batch, is in the range from 1 to 50% by weight.

6. The batch according to claim 5 , comprising at least 1% by weight of the grains for the production of the sintered refractory product comprised by the batch, in relation to the total weight of the batch.

7. The batch according to claim 5 , comprising 1 to 15% by weight of the grains for the production of the sintered refractory product comprised by the batch, in relation to the total weight of the batch.

8. The batch according to claim 5 , comprising at least one calcium oxide comprising component.

9. The batch according to claim 8 , wherein the at least one calcium oxide comprising component is at least one of the following calcium oxide comprising components: Doloma or dolomite.

10. The batch according to claim 8 , wherein the at least one calcium oxide comprising component is present in the form of grains.

11. The batch according to claim 5 , wherein the batch is a batch for the production of a sintered refractory dolomite product.

12. The batch according to claim 5 , wherein the batch has a chemical composition with MgO in the range from 38 to 90% by mass and with CaO in the range from 8 to 60, the remainder being ZrO 2 , SiO 2 , Fe 2 O 3 , and Al 2 O 3 .

13. A process for the production of a sintered refractory product, the process comprising the following steps:
14.1 providing a batch, the batch comprising grains for the production of the sintered refractory product, the grains for the production of the sintered refractory product comprising the following features:
14.1.1 the grains for the production of the sintered refractory product are made of at least one of the following:
14.1.1.1 grains made of magnesia, the surface of which have a coating of zirconia at least in sections; or
14.1.1.2 grains made of magnesite, the surface of which have a coating of zirconia at least in sections; or
14.1.1.3 grains made of doloma, the surface of which have a coating of zirconia at least in sections; or
14.1.1.4 grains made of dolomite, the surface of which have a coating of zirconia at least in sections;

14.1.2 the grains for the production of the sintered refractory product comprised by the batch have a grain size of at least 2.8 mm;
14.1.3 wherein the proportion by weight of the coating of zirconia, in relation to the total weight of the grains for the production of the sintered refractory product comprised by the batch, is in the range from 1 to 50% by weight;

14.2 firing the batch to produce a sintered refractory product.

14. A sintered refractory product, the product comprising the following features:
15.1 the product comprises grains, which are sintered together;
15.2 the grains comprise first grains and second grains, wherein
15.3 the first grains comprise a subset of grains that comprise calcium oxide, wherein
15.4 the second grains are at least one of the following:
15.4.1 magnesia grains, the surface of which have a coating of calcium zirconate at least in sections; or
15.4.2 magnesite grains, the surface of which have a coating of calcium zirconate at least in sections; or
15.4.3 doloma grains, the surface of which have a coating of calcium zirconate at least in sections; or
15.4.4 dolomite grains, the surface of which have a coating of calcium zirconate at least in sections; and wherein

15.5 the second grains have a grain size of at least 2.8 mm;
15.6 the proportion by weight of the coating of zirconia, in relation to the total weight of the second grains, is in the range from 1 to 50% by weight.

Assignees

• Refractory Intellectual Property Gmbh & Co Kg

Inventors

• Kerr Jacob
• O'Brien Robert

Classifications

• C04B2235/96

  Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance · CPC title

• C04B2235/80

  Phases present in the sintered or melt-cast ceramic products other than the main phase · 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

• C04B35/62823 Primary

  Zirconium or hafnium oxide · CPC title

• C04B35/06

  based on oxide mixtures derived from dolomite · CPC title