Large diameter slag wool, composition and method of making same

Patent metadata

Field	Value
Publication number	US-9796635-B1
Application number	US-201615189662-A
Country	US
Kind code	B1
Filing date	Jun 22, 2016
Priority date	Jun 22, 2016
Publication date	Oct 24, 2017
Grant date	Oct 24, 2017

Abstract

The disclosure provides a slag wool composition including about 60 to about 80 wt. % blast furnace slag and about 20 to about 40 wt. % basalt, based on the total weight of the inorganic raw materials, wherein the composition has an A/B ratio in a range of about 1.20 to about 1.70. The disclosure further provides a slag wool produced using the slag wool composition of the disclosure, wherein the slag wool has a fiber diameter in a range of about 4.0 microns to about 10.0 microns. The disclosure further provides a method for the manufacture of slag wool.

First claim

What is claimed:

1. A slag wool composition comprising:
about 60 wt. % to about 80 wt. % blast furnace slag; and
about 20 wt. % to about 40 wt. % basalt, based on the total weight of the inorganic raw materials;
wherein the composition has an A/B ratio in a range of about 1.20 to about 1.70 wherein the basalt comprises about 47.5 wt. % to about 49.5 wt. % SiO 2 , about 8.4 wt. % to about 9.5 wt. % CaO, about 5.9 wt. % to about 7.0 wt. % MgO, about 14.5 wt. % to about 15.5 wt. % Al 2 O 3 , about 13.0 wt. % to about 14.0 wt. % Fe 2 O 3 , about 2.0 wt. % to about 3.0 wt. % Na 2 O, about 0.15 wt. % to about 0.25 wt. % P 2 O 5 , about 0.55 wt. % to about 0.85 wt. % K 2 O, about 1.65 wt. % to about 2.00 wt. % TiO 2 , about 0.15 wt. % to about 0.25 wt. % Mn 2 O 3 , up to about 0.01 wt. % SO 3 , about 0.02 wt. % to about 0.04 wt. % SrO, about 0.01 wt. % to about 0.03 wt. % Cr 2 O 3 , about 0.01 wt. % to about 0.03 wt. % ZnO, and about 0.02 wt. % to about 0.04 wt. % BaO.

2. The slag wool composition of claim 1 , wherein the composition has an A/B ratio in a range of about 1.25 to about 1.65.

3. The slag wool composition of claim 1 , wherein the composition has an A/B ratio in a range of about 1.25 to about 1.60.

4. The slag wool composition of claim 1 , consisting essentially of the blast furnace slag and the basalt.

5. A slag wool composition comprising:
about 60 wt. % to about 80 wt. % blast furnace slag; and
about 20 wt. % to about 40 wt. % basalt, based on the total weight of the inorganic raw materials;
wherein the composition has an A/B ratio in a range of about 1.20 to about 1.70, wherein the blast furnace slag comprises about 35.0 wt. % to about 40.5 wt. % SiO 2 , about 35.5 wt. % to about 40.6 wt. % CaO, about 10.3 wt. % to about 11.4 wt. % MgO, about 8.4 wt. % to about 9.8 wt. % Al 2 O 3 , about 0.2 wt. % to about 0.3 wt. % Fe 2 O 3 , about 0.1 wt. % to about 0.3 wt. % Na 2 O, up to about 0.01 wt. % P 2 O 5 , about 0.3 wt. % to about 0.5 wt. % K 2 O, about 0.2 wt. % to about 0.5 wt. % TiO 2 , about 0.15 wt. % to about 0.55 wt. % Mn 2 O 3 , about 0.3 wt. % to about 1.2 wt. % SO 3 , about 0.04 wt. % to about 0.06 wt. % SrO, up to about 0.01 wt. % Cr 2 O 3 , up to about 0.01 wt. % ZnO, and about 0.03% to about 0.05 wt. % BaO.

6. The slag wool composition of claim 5 , wherein the composition has an A/B ratio in a range of about 1.25 to about 1.65.

7. The slag wool composition of claim 5 , wherein the composition has an A/B ratio in a range of about 1.25 to about 1.60.

8. A slag wool produced using the composition of claim 5 , wherein the slag wool has a fiber diameter in a range of about 4.0 microns to about 10.0 microns.

9. A slag wool produced using the composition of claim 1 , wherein the slag wool has a fiber diameter in a range of about 4.0 microns to about 10.0 microns.

10. The slag wool of claim 9 , wherein the slag wool has a shot content of about 50% or less.

11. The slag wool of claim 9 , wherein the slag wool has a shot content of about 45% or less.

12. The slag wool of claim 9 , wherein the slag wool has a shot content of about 40% or less.

13. The slag wool of claim 9 , wherein the slag wool has an A/B ratio in a range of 1.20 to about 1.70.

14. The slag wool of claim 9 , wherein the composition has an A/B ratio in a range of about 1.25 to about 1.65.

15. The slag wool of claim 9 , wherein the composition has an A/B ratio in a range of about 1.25 to about 1.60.

16. The slag wool of claim 9 , wherein the slag wool has a shot content of about 50% or less.

17. The slag wool of claim 9 , wherein the slag wool has a shot content of about 40% or less.

18. The slag wool of claim 9 , wherein the slag wool has an A/B ratio in a range of 1.20 to about 1.70.

19. A method for the manufacture of slag wool, comprising:
providing a composition comprising about 60 wt. % to about 80 wt. % blast furnace slag and about 10 wt. % to about 40 wt. % basalt, based on the total weight of the inorganic raw materials, such that the composition has an A/B ratio in a range of about 1.20 to about 1.70; heating the composition in a cupola or open furnace, further comprising providing coke such that the weight ratio of blast furnace slag and basalt to coke ((blast furnace slag+basalt)/coke) is about 6.9.

20. The method of claim 19 , wherein the composition has an A/B ratio in a range of 1.25 to about 1.65.

21. The method of claim 19 , wherein the composition has an A/B ratio in a range of 1.25 to about 1.60.

22. The method of claim 19 , wherein the composition consists essentially of the blast furnace slag and the basalt.

23. The method of claim 14 , wherein the blast furnace slag comprises about 35.0 wt. % to about 40.5 wt. % SiO 2 , about 35.5 wt. % to about 40.6 wt. % CaO, about 10.3 wt. % to about 11.4 wt. % MgO, about 8.4 wt. % to about 9.8 wt. % Al 2 O 3 , about 0.2 wt. % to about 0.3 wt. % Fe 2 O 3 , about 0.1 wt. % to about 0.3 wt. % Na 2 O, up to about 0.01 wt. % P 2 O 5 , about 0.3 wt. % to about 0.5 wt. % K 2 O, about 0.2 wt. % to about 0.5 wt. % TiO 2 , about 0.15 wt. % to about 0.55 wt. % Mn 2 O 3 , about 0.3 wt. % to about 1.2 wt. % SO 3 , about 0.04 wt. % to about 0.06 wt. % SrO, up to about 0.01 wt. % Cr 2 O 3 , up to about 0.01 wt. % ZnO, and about 0.03% to about 0.05 wt. % BaO.

24. The method of claim 19 , wherein the basalt comprises about 47.5 wt. % to about 49.5 wt. % SiO 2 , about 8.4 wt. % to about 9.5 wt. % CaO, about 5.9 wt. % to about 7.0 wt. % MgO, about 14.5 wt. % to about 15.5 wt. % Al 2 O 3 , about 13.0 wt. % to about 14.0 wt. % Fe 2 O 3 , about 2.0 wt. % to about 3.0 wt. % Na 2 O, about 0.15 wt. % to about 0.25 wt. % P 2 O 5 , about 0.55 wt. % to about 0.85 wt. % K 2 O, about 1.65 wt. % to about 2.00 wt. % TiO 2 , about 0.15 wt. % to about 0.25 wt. % Mn 2 O 3 , up to about 0.01 wt. % SO 3 , about 0.02 wt. % to about 0.04 wt. % SrO, about 0.01 wt. % to about 0.03 wt. % Cr 2 O 3 , about 0.01 wt. % to about 0.03 wt. % ZnO, and about 0.02 wt. % to about 0.04 wt. % BaO.

Assignees

• Usg Interiors Llc

Inventors

• Luan Wenqi
• Brown Martin
• Keller Tanya
• Hill Mike
• Bogen Scott A
• Figi Carlos
• Frank William

Classifications

• Y02P40/57

  Improving the yield, e-g- reduction of reject rates · CPC title

• C03B37/04

  by using centrifugal force {, e.g. spinning through radial orifices; Construction of the spinner cups therefor (bonder application C03C25/00)} · CPC title

• C03C2213/02

  Biodegradable glass fibres · CPC title

• C03C3/097

  containing phosphorus, niobium or tantalum · CPC title

• C03C13/06

  Mineral fibres, e.g. slag wool, mineral wool, rock wool · CPC title