Sintered zircon material for forming block

Patent metadata

Field	Value
Publication number	US-11465940-B2
Application number	US-201916384462-A
Country	US
Kind code	B2
Filing date	Apr 15, 2019
Priority date	Mar 31, 2014
Publication date	Oct 11, 2022
Grant date	Oct 11, 2022

Abstract

A refractory object may include a zircon body that may include at least about 0.1 wt. % and not greater than about 5.5 wt. % of an Al2O3 containing component for a total weight of the zircon body. The zircon body may further include at least about 25 wt. % and not greater than about 35 wt. % of a SiO2 component for a total weight of the zircon body.

First claim

What is claimed is:

1. A refractory object comprising: a zircon body, wherein the zircon body comprises:
at least 1.0 wt. % and not greater than 5 wt. % of an Al 2 O 3 containing component for a total weight of the zircon body;
at least 25 wt. % and not greater than 30.0 wt. % of a SiO 2 component in wt. % for a total weight of the zircon body; and
a ratio CB SIO2 /CB AlC of at least 5 and not greater than 30, wherein CB SiO2 represents a content of a SiO 2 component in wt. % for a total weight of the zircon body and CB AlC represents a content of the Al 2 O 3 containing component in wt. % for a total weight of the zircon body.

2. The refractory object of claim 1 , wherein the zircon body comprises a ratio CB SiO2 /CB AlC of at least about 10.

3. The refractory object of claim 1 , wherein the zircon body comprises a ratio CB SiO2 /CB AlC of not greater than about 25.

4. The refractory object of claim 1 , wherein the zircon body comprises a content of zircon of at least about 50 wt. % for a total weight of the zircon body.

5. The refractory object of claim 1 , wherein the zircon body comprises a creep deformation rate of not greater than about 1.0 E-4 h −1 as measured using a three point bend test at a temperature of 1350° C. and a stress of 2 MPa.

6. The refractory object of claim 1 , wherein the zircon body comprises a creep deformation rate of not greater than about 4.9 E-5 h −1 as measured using a four point bend test at a temperature of 1350° C. and a stress of 2 MPa.

7. The refractory object of claim 1 , wherein the zircon body has a density of not greater than about 4.5 g/cm 3 .

8. The refractory object of claim 1 , wherein the zircon body comprises an apparent porosity of not greater than about 15 vol. % for a total volume of the zircon body.

9. The refractory object of claim 1 , wherein the zircon body comprises a blistering value of not greater than about 8 bubbles per mm 2 measured after 8 hours at a temperature of 1200° C.

10. The refractory object of claim 1 , wherein the zircon body comprises a blistering value of not greater than about 1 bubble per mm 2 measured after 360 hours at a temperature of 1200° C.

11. The refractory object of claim 1 , wherein the zircon body comprises a ratio of CB AlC /CB Z of not greater than about 0.08, where CB AlC represents a content of the Al 2 O 3 containing component in wt. % for a total weight of the zircon body and CBz represents a content of zircon in wt. % for the total weight of the zircon body.

12. The refractory object of claim 1 , wherein the zircon body comprises a ratio of CB AlC /CB Z of at least about 0.002, where CB AlC represents a content of the Al 2 O 3 containing component in wt. % for a total weight of the zircon body and CBz represents a content of zircon in wt. % for the total weight of the zircon body.

13. The refractory object of claim 1 , wherein the zircon body comprises a ratio CB Ta2O5 /CB SiO2 of at least about 0.001, where CB Ta2O5 represents a content of Ta 2 O 5 in wt. % for a total weight of the zircon body and CB SiO2 represents a content of a SiO 2 component in wt. % for a total weight of the zircon body.

14. The refractory object of claim 1 , wherein the zircon batch comprises a ratio CM Ta2O5 /CM SiO2 of not greater than about 0.5, where CM Ta2O5 represents a content of Ta 2 O 5 in wt. % for a total weight of the zircon batch and CM SiO2 represents a content of a SiO 2 component in wt. % for a total weight of the zircon batch.

15. The refractory object of claim 1 , wherein the Al 2 O 3 containing component comprises mullite.

16. The refractory object of claim 15 , wherein the mullite comprises Al 6 Si 2 O 13 .

Assignees

• Saint Gobain Ceramics

Inventors

• Fourcade Julien P
• Lechevalier David J
• Citti Olivier

Classifications

• C04B2235/6567

  Treatment time · CPC title

• C04B2235/3217

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

• C04B2235/3287

  Germanium oxides, germanates or oxide forming salts thereof, e.g. copper germanate · CPC title

• C04B35/62685

  characterised by the order of addition of constituents or additives · CPC title

• C03B17/064

  by the overflow downdraw fusion process; Isopipes therefor · CPC title