Bonded zirconia refractories and methods for making the same

Abstract

Disclosed herein are methods for making a bonded refractory material, the methods comprising preparing a slurry comprising glass precursor particles having an average particle size ranging from about1 nm to about 200 nm; combining zirconia particles with the slurry to form a batch composition comprising at least about 80% by weight of zirconia; forming a green body from the batch composition; andsintering the green body to form a sintered refractory material. Sintered high-zirconia refractory materials can comprise at least about 80% by weight of zirconia having an average grain size of 100microns or less, wherein the zirconia is interspersed in a glassy phase, and wherein the sintered refractory materials comprise about 15% or less by weight of the glassy phase. Melting vessels havingat least one interior surface comprising such sintered zirconia refractory materials are further disclosed herein.

Description

[0001] Cross References to Related Applications [0002] This application claims the benefit of priority under 35 U.S.C. §119 to U.S. Provisional Application Serial No. 62 / 152,458, filed April 24, 2015, upon which this application is based and incorporated by reference in its entirety This article. technical field [0003] The present disclosure relates generally to refractory materials and methods for making the same, and more particularly to high zirconia refractory materials comprising a combination of fine-grained microstructure and dispersed glassy phase. Background technique [0004] Furnaces and melting vessels are used to melt various batch materials such as glass and metal batches, etc. The batch can be placed in a container with two or more electrodes and melted by applying a voltage to the electrodes and / or by applying an external heat source such as a burner. The life cycle of a furnace may depend, for example, on the wear of the refractory material of which th...

AI Technical Summary

Problems solved by technology

This may be due in part to various difficulties in managing the manufacturing process, for example due to phase transitions at high temperatures, which can cause stress and / or significant volume changes in the refractory

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