# US 9,040,442 B2 · Shaped or unshaped refractory or kiln furniture composition

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- Number: US 9,040,442 B2
- Document ID: US9040442B2
- Status: Granted
- Kind: B2
- Application number: 14/004,980
- Filed: 2012-03-20
- Published: 2014-01-23
- Granted: 2015-05-26
- Earliest claimed: 2012-03-20
- Assignees: Center for Abrasives and Refractories Research & Development C.A.R.R.D. GmbH
- Applicants: Xiaoyong Xiong; Michael Weissenbacher
- Inventors: Xiaoyong Xiong; Michael Weissenbacher
- Web page: https://patentgrep.com/patent/US9040442B2

## CPC

- C04B 35/101: Refractories from grain sized mixtures
- C04B 35/03: based on magnesium oxide, calcium oxide or oxide mixtures derived from dolomite
- C04B 35/047: containing chromium oxide or chrome ore
- C04B 35/06: based on oxide mixtures derived from dolomite
- C04B 35/14: based on silica
- C04B 35/18: rich in aluminium oxide
- C04B 35/185: Mullite {3Al2O3-2SiO2}
- C04B 35/20: rich in magnesium oxide {, e.g. forsterite (C04B35/195 takes precedence)}
- C04B 35/443: Magnesium aluminate spinel
- C04B 35/565: based on silicon carbide
- C04B 35/6316: {Binders based on silicon compounds}
- C04B 35/66: Monolithic refractories or refractory mortars, including those whether or not containing clay {(making or repairing of linings F27D1/16)}
- F23M 5/04: Supports for linings
- C04B 2235/3272: Iron oxides or oxide forming salts thereof, e.g. hematite, magnetite
- C04B 2235/5409: expressed by specific surface values
- C04B 2235/5436: micrometer sized, i.e. from 1 to 100 micron
- C04B 2235/5445: submicron sized, i.e. from 0,1 to 1 micron
- C04B 2235/5463: Particle size distributions
- C04B 2235/5472: Bimodal, multi-modal or multi-fraction
- C04B 2235/5481: Monomodal
- F23M 2900/05004: Special materials for walls or lining
- 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
- F23M: CASINGS, LININGS, WALLS OR DOORS SPECIALLY ADAPTED FOR COMBUSTION CHAMBERS, e.g. FIREBRIDGES; DEVICES FOR DEFLECTING AIR, FLAMES OR COMBUSTION PRODUCTS IN COMBUSTION CHAMBERS; SAFETY ARRANGEMENTS SPECIALLY ADAPTED FOR COMBUSTION APPARATUS; DETAILS OF COMBUSTION CHAMBERS, NOT OTHERWISE PROVIDED FOR

## Abstract

The present description relates to a refractory composition including 70 weight percent to 98 weight percent particulate refractory material and 2 weight percent to 30 weight percent of a binder phase including reactive filler and a binder, the binder phase substantially includes solely reactive andalusite as reactive filler.

## Claims

### Claim 1

A shaped or unshaped refractory or kiln furniture composition comprising 70 weight percent to 98 weight percent particulate refractory material and 2 weight percent to 30 weight percent of a binder phase comprising a reactive filler and a binder,
wherein the binder phase substantially comprises solely reactive andalusite having an average particle size d50 between 0.2 μm and 2.0 μm as reactive filler, and wherein the reactive andalusite has a narrow particle size distribution having a width of particles sizes in a range of less than 2.5 μm.

### Claim 2 (depends on 1)

The composition according to claim 1, wherein the reactive andalusite has an average particle size d50 between 0.5 μm and 1.5 μm.

### Claim 3 (depends on 1)

The composition according to claim 1, wherein the reactive andalusite has a specific surface area ranging from 10 m2/g to 25 m2/g.

### Claim 4 (depends on 1)

The composition according to claim 1, wherein the particulate refractory material is selected from the group consisting of silica, silicon carbide, alumina, bauxite, spinel, calcined dolomite, chrome magnesite, olivine, forsterite, mullite, kyanite, silimanite, andalusite, chamotte, or a mixture of two or more of those materials.

### Claim 5 (depends on 1)

A refractory casted piece comprising the refractory composition according to claim 1, wherein the casted piece is sintered at a temperature ranging from 1100° C. to 1400° C., has a Cold Module of Rupture measured according to EN 1402-5 of more than 5 MPa, and a Cold Crush Strength measured according to EN 1402-6 of more than 30 MPa.

### Claim 6 (depends on 5)

The refractory casted piece according to claim 5, wherein the composition is a low cement castable having a cement content of about 5 weight percent.

### Claim 7 (depends on 5)

The refractory casted piece according to claim 5, wherein the composition is an ultra-low cement castable having a cement content of about 2 weight percent.

### Claim 8 (depends on 1)

A refractory ramming material comprising the refractory composition according to claim 1, wherein the refractory ramming material is configured to be sintered at a temperature ranging from 1100° C. to 1750° C., and following sintering, has a Cold Module of Rupture measured according to EN 1402-5 of more than 5 MPa, and a Cold Crush Strength according to EN 1402-6 of more than 30 MPa.

### Claim 9 (depends on 1)

A refractory gunning material comprising the refractory composition according to claim 1, wherein the refractory gunning material is configured to be sintered at a temperature ranging from 1100° C. to 1750° C., and following sintering, has a Cold Module of Rupture measured according to EN 1402-5 of more than 3 MPa, and a Cold Crush Strength according to EN 1402-6 of more than 20 MPa.

### Claim 10 (depends on 1)

A fired refractory brick comprising the refractory composition according to claim 1, wherein the fired refractory brick is sintered at a temperature ranging from 1100° C. to 1750° C., has a Cold Module of Rupture measured according to EN 1402-5 of more than 8 MPa, and a Cold Crush Strength according to EN 1402-6 of more than 50 MPa.

### Claim 11 (depends on 1)

A kiln furniture comprising the refractory composition according to claim 1, wherein the kiln furniture is sintered at a temperature ranging from 1100° C. to 1750° C., has a Cold Module of Rupture measured according to EN 1402-5 of more than 8 MPa, and a Cold Crush Strength according to EN 1402-6 of more than 30 MPa.