Pumpable casting composition and method of use

A method of manufacturing a refractory liner, comprising the steps of:

• forming a casting composition including about 36-92 % by weight silicon carbide, about 8-20% by weight aqueous colloidal silica having an average particle diameter of 4-100 millimicrons, zero to about 10% by weight free carbon, and zero to about 50% by weight of an alumina component;
• transporting the casting composition to a molten metal containment device using a pump;
• and
• forming a refractory liner from the casting composition in situ in the metal containment device.

A method of forming a refractory liner, comprising the steps of:

• forming a lower refractory layer using a casting composition which includes about 55-90% by weight of a granular base material selected from the group consisting of calcined clay, mullite, brown fused alumina, tabular alumina and mixtures thereof, a colloidal silica binder having an average particle diameter of 4-100 millimicrons, and up to about 35 % by weight silicon carbide;
• hardening the lower refractory layer;
• forming an upper refractory layer above the lower refractory layer using a casting composition which includes about 36-92 % by weight silicon carbide, a colloidal silica binder having an average particle diameter of 4-100 millimicrons, zero to about 10% by weight graphite, and zero to about 50% by weight of an alumina component;
• hardening the upper refractory layer;
• and
• heating the upper and lower refractory layers at above 250.degree. F.