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Refractory composition and process for forming article therefrom

a technology of phosphoric acid and composition, which is applied in the direction of immunoglobulins, solid waste management, peptides, etc., can solve the problems of reducing the strength properties of cement formed with extra phosphoric acid relative to cast precured, mechanical failure, and limiting the high temperature limit of operation of the resulting material, etc., to achieve the effect of improving the handling characteristics and the strength of the articl

Inactive Publication Date: 2013-08-15
STELLAR MATERIALS
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The invention provides stronger refractory compositions with higher densities and cold crush strengths. These compositions have improved performance compared to previous options.

Problems solved by technology

Adhesion of these ambient temperature cured materials occurs because of the rough surface and while convenient to bond at ambient temperature are comparatively weak as compared to elevated temperature cured material and also tend to suffer from mechanical failure during heat up or when exposed to thermal stresses.
Unfortunately, alkali phosphates are characterized by low melting points that limit the high temperature limit of operation for the resulting material.
As a result, cement strengthening through densification is largely precluded as are often desirable handling methods such as pumping or shotcreting unless extra phosphoric acid is added to improve precured cement mixture flowability and extend working times. However, the addition of more phosphoric acid alters the phosphate:alkali ratio in the precured cement mixture and thereby invariably reduces the strength properties of cement formed with extra phosphoric acid relative to a cast precured cement mixture lacking additional phosphoric acid.
As a result of these limitations, alkali phosphate binder system based refractory cements have met with limited acceptance.

Method used

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Examples

Experimental program
Comparison scheme
Effect test

example 1

[0024]5% aluminum metaphosphate was mixed into bauxite aggregate along with 4½ total weight percent water and 0.1% polyethylene glycol having a molecular weight of more than 300 grams per mole. Upon drying and firing at 800° Celsius. for 5 hours, a ceramic was obtained having a crystalline aluminum orthophosphate continuous binder matrix phase as determined by x-ray powder diffraction.

example 2

[0025]The slurry of Example 1 was modified to include 5% by slurry weight calcium aluminate cement with comparable results.

example 3

[0026]To the slurry of Example 2, dry sodium silicate was added to 0.015 total percent. An increase in green strength is noted and faster setting time that facilitated ease of demolding and also produced a crystalline aluminum orthophosphate matrix phase.

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Abstract

A refractory composition and processes for manufacture are provided where the compositions possess improved refractory alkali resistance and superior handling properties. Compositions and processes for their manufacture may include a plurality of ceramic particles and a binder sintered to the particles wherein the binder includes crystalline aluminum orthophosphate distributed as the result of an in situ reaction of aluminum metaphosphate with alumina. Kits provided according to the invention provide materials for use in manufacture of a composition where the kit includes aluminum metaphosphate and a nonfacile additive.

Description

REFERENCE TO RELATED APPLICATIONS[0001]This application claims priority from U.S. Provisional Patent Application Ser. No. 61 / 316,602 filed Mar. 23, 2010, the contents of which are incorporated herein by reference.FIELD OF THE INVENTION[0002]The present invention in general relates to a refractory composition and process for forming an article therefrom, and in particular a composition having crystalline AlPO4 formed in the composition binder alone or with other binder components to produce an article with exceptional refractory corrosion resistance.BACKGROUND OF THE INVENTION[0003]Cement bonded materials largely form only mechanical bonds at ambient temperature of 20° Celsius. Adhesion of these ambient temperature cured materials occurs because of the rough surface and while convenient to bond at ambient temperature are comparatively weak as compared to elevated temperature cured material and also tend to suffer from mechanical failure during heat up or when exposed to thermal stres...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): C04B35/10C04B35/14C04B35/622C04B35/565
CPCA61K38/1709C12N2750/14151A61K45/06C07K16/081C07K16/18C12N15/86C12N2750/14143C12N2750/14145C12N2810/6027A61K38/21C12N2750/14122C12N7/00C07K14/005A61K31/522A61K38/00A61K48/0058C04B35/10C04B35/14C04B35/565C04B35/622A61K48/0008A61K2300/00C04B12/022C04B12/027C04B28/34C04B35/101C04B35/185C04B35/6263C04B35/62665C04B35/6309C04B35/63488C04B35/66C04B35/76C04B2111/00431C04B2111/28C04B2235/3201C04B2235/3208C04B2235/3217C04B2235/3222C04B2235/3427C04B2235/6027C04B2235/656C04B2235/77C04B2235/96C04B2235/9615Y02W30/91C04B7/32C04B14/303C04B18/146C04B14/48C04B40/0071C04B40/0263C04B12/04C04B24/32C04B14/324C04B33/04C04B33/32C04B35/657C04B2235/447C04B2235/48C04B2235/524
Inventor DECKER, JENS
Owner STELLAR MATERIALS
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