Zircon refractories with improved thermal shock resistance
AssigneeCorhart Refractories Corporation
InventorsThomas M. Wehrenberg, Charles N. McGarry, Sylvie Mahe, Douglas A. Drake
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Abstract
Dense zircon refractories having improved thermal shock damage resistance for use in glass melt or high alkali vapor contact applications comprise, and, consist essentially of, about fifty percent by weight or more ZrSiO.sub.4, at least about one percent zirconia in particle form distributed substantially uniformly throughout the composition of the refractory, and optionally, a zircon grain growth enhancing composition, preferably TiO.sub.2.
Claims35
A dense zircon refractory with high glass corrosion resistance having improved thermal shock resistance produced by a method comprising the steps of:
- forming into a shape a green composition of mixed sinterable components in particle form, the mixed sinterable components consisting essentially of about 75% to 95% by weight zircon and about 5% to 25% by weight zirconia with one or more zircon grain growth enhancing agents including TiO.sub.2, the sinterable components collectively including at least 0.10% by weight TiO.sub.2 ;
- and
- firing the shape to a temperature throughout of between about 1400.degree. C. and 1650.degree. C. for a time sufficient to sinter the zircon.
A dense zircon refractory with high glass corrosion resistance having improved thermal shock resistance produced by the method comprising the steps of:
- forming into a shape a green composition of mixed sinterable components in particle form, the mixed sinterable components consisting essentially of about 75% to 95% by weight zircon particles and about 5% to 25% by weight zirconia particles with one or more zircon grain growth enhancing agents including TiO.sub.2, the zircon particles having a median particle size greater than a median particle size of the zirconia particles;
- and
- firing the shape to a temperature throughout of between about 1400.degree. C. and 1650.degree. C. for a time sufficient to sinter the zircon.
A dense zircon refractory composition with high glass corrosion resistance having improved thermal shock resistance consisting essentially of:
- about 72 to 94% by weight ZrSiO.sub.4,
- at least 0.10% by weight TiO.sub.2, and
- about 5 to 25% by weight ZrO.sub.2 and HfO.sub.2 ;
- and the composition being substantially in the form of a matrix of aggregated zircon particles with individual zirconia particles substantially uniformly distributed through the matrix.
A dense zircon refractory composition with a high glass corrosion resistance having improved thermal shock resistance consisting of, by oxide analysis:
- about 25 to 33% SiO.sub.2,
- about 66 to 72% ZrO.sub.2 and HfO.sub.2,
- 0.10 to about 4% TiO.sub.2, and
- about 5% or less other materials;
- and the composition being substantially in the form of a matrix of aggregated zircon particles with zirconia particles distributed substantially uniformly through the matrix.
Dependencies are inferred from the claim text.