Refractory bricks

Patent metadata

Field	Value
Publication number	US-2018244577-A1
Application number	US-201615755085-A
Country	US
Kind code	A1
Filing date	Aug 24, 2016
Priority date	Aug 25, 2015
Publication date	Aug 30, 2018
Grant date	—

Abstract

A process for preparing a refractory brick, comprises:
mixing a refractory aggregate and a binder composition to obtain a refractory mixture wherein the binder composition comprises:

(a) carbohydrate reactant(s) comprising reducing sugar(s) or carbohydrate reactant(s) that yield reducing sugar(s) in situ under thermal conditions and nitrogen-containing reactant(s) and/or
(b) curable reaction product(s) of reducing sugar(s) and nitrogen-containing reactant(s)
pressing the refractory mixture to obtain a moulded refractory brick; and firing the moulded refractory brick.

First claim

1 . A process for preparing a refractory brick, comprising
mixing a refractory aggregate and a binder composition to obtain a refractory mixture wherein the binder composition comprises: (a) carbohydrate reactant(s) comprising reducing sugar(s) or carbohydrate reactant(s) that yield reducing sugar(s) in situ during firing and nitrogen-containing reactant(s) and/or (b) reaction product(s), notably curable reaction products, of reducing sugar(s) and nitrogen-containing reactant(s) pressing the refractory mixture to obtain a moulded refractory brick; and firing the moulded refractory brick.

2 . A process in accordance with claim 1 wherein the binder composition is a solid binder composition.

3 . A process in accordance with claim 1 wherein the binder composition is an aqueous binder composition having a solid content in the range of 40 wt % to 85 wt % determined as bake out solids by weight after drying at 140° C. for 2 hours.

4 . A process in accordance with claim 1 wherein the binder composition is substantially formaldehyde free.

5 . A process in accordance with claim 1 wherein the process is substantially free of ammonia emission.

6 . A process in accordance with claim 1 wherein the process is substantially free of sulphur emission.

7 . A process in accordance with claim 1 wherein moulded refractory brick, prior to firing, comprises between 0.5 wt % and 5 wt % of the binder composition measured by loss on ignition.

8 . A process in accordance with claim 1 wherein the binder composition comprises
(i) between 50% to 99% by dry weight, preferably between 75% to 95 by dry weight of carbohydrate reactant(s) comprising reducing sugar(s) and/or carbohydrate reactant(s) that yield reducing sugar(s) in situ during firing; and
(ii) between 1% to 50% by dry weight, preferably between 5% to 25% by dry weight, of nitrogen-containing reactant(s).

9 . A process in accordance with claim 1 wherein the binder composition when mixed with the refractory aggregate comprises at least 50% by dry weight of reaction products of nitrogen containing reactant(s) and reducing sugar reactant(s).

10 . A process in accordance with claim 1 wherein the nitrogen-containing reactant(s) are selected from the group consisting of a primary amine, a di-primary diamine, HMDA and combinations thereof.

11 . A process in accordance with claim 1 wherein the carbohydrate reactant(s) are selected from the group consisting of dextrose, fructose, xylose, and mixtures thereof.

12 . A process in accordance with claim 1 wherein the refractory aggregate comprises magnesite, dolomite, alumina, oxides, bauxite, quartz, carbonates, ores, clay, silica, chromite, and combination thereof.

13 . A refractory brick obtained by the process of claim 1 .

Assignees

• Knauf Insulation Ltd
• Knauf Insulation Doo Skofja Loka
• Knauf Insulation Sprl
• Knauf Insulation Inc

Inventors

• Koessler Stefan

Classifications

• C04B35/101

  Refractories from grain sized mixtures · CPC title

• C04B35/636

  Polysaccharides or derivatives thereof · CPC title

• C04B2235/604

  Pressing at temperatures other than sintering temperatures · CPC title

• C04B35/047 Primary

  containing chromium oxide or chrome ore · CPC title

• C04B35/106

  containing zirconium oxide or zircon (ZrSiO4) · CPC title