Refractory composition and process for forming article therefrom
AssigneeStellar Materials Incorporated
InventorJens Decker
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Abstract
A refractory composition and processes for manufacture are provided where the compositions possess improved refractory alkali resistance and superior handling properties. Compositions and processes for their manufacture may include a plurality of ceramic particles and a binder sintered to the particles wherein the binder includes crystalline aluminum orthophosphate distributed as the result of an in situ reaction of aluminum metaphosphate with alumina. Kits provided according to the invention provide materials for use in manufacture of a composition where the kit includes aluminum metaphosphate and a nonfacile additive.
Claims19
A refractory composition comprising:
- a plurality of aggregate ceramic particles;
- a binder sintered to said plurality of aggregate ceramic particles, said binder comprising crystalline aluminum orthophosphate distributed in said binder as the result of reaction of aluminum metaphosphate with alumina;
- and
- a nonfacile additive of calcium aluminate cement, sodium silicate, polyphosphate, or organic salts.
A process of forming a refractory article comprising:
- mixing aluminum metaphosphate particulate with a mixed metal oxide in the presence of less than 10 slurry weight percent of water or an organic solvent to form a mixture, where said mixed metal oxide comprises a metal selected from the group consisting of Sb, Bi, B, Cr (III), Er, Gd (III), In (III), Ni (III), Rh (III), Sm (III), Sc (III), Tb (III), Ti (III), NV (III), V (III), Yb (III), and Y (III);
- heating said mixture to a temperature and for a time sufficient to induce the reaction to form a mixed metal orthophosphate.
A kit for producing a refractory binder comprising aluminum metaphosphate and a nonfacile additive comprising calcium aluminate cement, sodium silicate, sodium polyphosphates, or combinations thereof.
Dependencies are inferred from the claim text.