# US 8,540,910 B2 · Method for producing a refractory material from aluminum residues

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- Number: US 8,540,910 B2
- Document ID: US8540910B2
- Status: Granted
- Kind: B2
- Application number: 13/106,061
- Filed: 2011-05-12
- Published: 2012-11-15
- Granted: 2013-09-24
- Earliest claimed: 2011-05-12
- Assignees: Atomic Energy Council-Institute of Nuclear Energy Research
- Applicants: Sheng-Fu Yang; Chun-Yen Yeh; Yen-Hua Chang; To-Mei Wang; Wen-Cheng Lee; Kin-Seng Sun; Chin-Ching Tzeng
- Inventors: Sheng-Fu Yang; Chun-Yen Yeh; Yen-Hua Chang; To-Mei Wang; Wen-Cheng Lee; Kin-Seng Sun; Chin-Ching Tzeng
- Web page: https://patentgrep.com/patent/US8540910B2

## CPC

- C04B 35/62204: {using waste materials or refuse (clay-wares containing waste materials C04B33/132)}
- C04B 33/138: from metallurgical processes, e.g. slag, furnace dust, galvanic waste
- C04B 35/18: rich in aluminium oxide
- C04B 35/6365: {Cellulose or derivatives thereof}
- C04B 2235/3201: Alkali metal oxides or oxide-forming salts thereof
- C04B 2235/3206: Magnesium oxides or oxide-forming salts thereof
- C04B 2235/3208: Calcium oxide or oxide-forming salts thereof, e.g. lime
- C04B 2235/3241: Chromium oxides, chromates, or oxide-forming salts thereof
- C04B 2235/3272: Iron oxides or oxide forming salts thereof, e.g. hematite, magnetite
- C04B 2235/3281: Copper oxides, cuprates or oxide-forming salts thereof, e.g. CuO or Cu2O
- C04B 2235/656: characterised by specific heating conditions during heat treatment
- C04B 2235/72: Products characterised by the absence or the low content of specific components, e.g. alkali metal free alumina ceramics
- C04B 2235/77: Density
- C04B 2235/96: Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
- Y02P 40/60: Production of ceramic materials or ceramic elements, e.g. substitution of clay or shale by alternative raw materials, e.g. ashes
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

Disclosed is a method for making a refractory material from aluminum residues of aluminum recycling. At first, the aluminum residues is mixed with adhesive solution so that the percentage by weight of the adhesive solution is 5 wt % to 10 wt %. The mixture is granulated into grains. The grains are filled in a mold, pressed and then removed from the mold so that the grains are turned into a green body. The green body is heated in a furnace at a range of temperature from 1100° C. to 1400° C. so that the grains are sintered and become a refractory material.

## Claims

### Claim 1

A method for making a refractory material comprising the steps of:
providing aluminum residues of aluminum recycling;
providing carboxylmethyl cellulose adhesive solution;
mixing the aluminum residues with the adhesive solution so that the adhesive solution takes up 5 wt % to 10 wt % of the mixture;
granulating the mixture into grains;
filling the grains in a mold;
pressing the grains with a uni-axial compressive force in the mold into a green body;
moving the green body from the mold; and
calcinating the green body at 1100° C. to 1400° C. in a furnace, thus sintering the green body into a refractory material,
wherein the resulting refractory material has a composition in weight percent of 63.52 to 80.8% Al2O3, 12.19 to 30.84% SiO2, 3.66 to 4.44% MgO, 0.54 to 1.05% Fe2O3, 0.56 to 0.72% CaO, 0.33 to 0.56% Na2O, 0.36 to 0.49% K2O, 0.06 to 0.2% CuO, and 0.03 to 0.07% Cr2O3.

### Claim 2 (depends on 1)

The method according to claim 1,
wherein the adhesive solution has a molecular formula of [C6H7O2(OH)2CH2OONa]n.

### Claim 3 (depends on 1)

The method according to claim 1,
wherein the refractory material comprises a firebrick selected from the group consisting of insulating firebricks, alumina firebricks, acid-resisting bricks, and clay firebrick.