Porous refractory objects and methods of forming

A method of forming a batch of refractory objects, comprising:

• forming a mixture including a ceramic material, an amorphous material, or a combination thereof, wherein forming the mixture comprises reducing a pressure on the mixture to remove gases in the mixture, wherein reducing the pressure on the mixture induces a mixing or rolling action in the mixture;
• and
• forming the mixture into a plurality of bodies of the refractory objects including a ceramic,
• wherein the batch comprises a first pore type of at least 23 vol % and not greater than 41 vol % for the volume of the batch, wherein an average maximum dimension of the first pore type is at least 0.1 mm and less than 2 mm;
• and a second pore comprising an average maximum pore dimension not greater than 60% of the average maximum pore dimension of the first pore type,
• wherein the batch comprises an average porosity of at least 25% to not greater than 75% for the volume of the batch, and
• wherein the batch comprises at least 50 refractory objects, a minimum volume of at least 0.36 cubic meters, and an average batch Porosity Index of not greater than 7.

A batch of refractory objects, comprising a plurality of bodies, each body of the plurality of bodies comprising a ceramic, wherein:

• the plurality of bodies comprises zircon;
• the batch comprises an average porosity of at least 25% to not greater than 75% for a volume of the batch,
• a first pore type comprises an average maximum dimension of at least 0.1 mm and less than 2 mm and comprises an irregular angular shape, wherein the first pore type is at least 40% and not greater than 79% of a total porosity (vol %) of the batch and the first pore type is at least 23 vol % and not greater than 41 vol % for the volume of the batch;
• and
• the batch comprises at least 50 refractory objects, a minimum volume of at least 0.36 cubic meters, and an average batch Porosity Index of not greater than 7, wherein Porosity Index is defined as [1×(number of pores of a pore size greater than 3 mm and not greater than or equal to 5 mm)+5×(number of pores having a pore size greater than 5 mm and not greater than or equal to 6.5 mm)+10×(number of pores having a pore size greater than 6.5 mm)] for each body of the plurality of bodies.