Plant and process for batch production and continuous feeding of refractory preparations

Abstract

A batch production and continuous feeding apparatus and process for batch production and continuous feeding of refractory formulations, comprising: a batch reactor (10) for controlled mixing of slurry; a product container (60) in communication with the batch reactor (10) to contain the mixed slurry; and a variable rate spray feeder or nozzle in communication with the product container and an air supply. A controller (100) controls the input, output and operation of the batch mixer (10) and monitors batch production. The controller (100) monitors the amount of slurry contained in the product container (60). If the slurry level in the product hopper is such that the product hopper cannot accommodate another batch of slurry, the controller interrupts batch production and resumes production when the product hopper can accept the contents of the batch reactor (10).

Description

Technical Field

[0001] The present application relates to a batch production and continuous feeding device and a process for batch production and continuous feeding of refractory material preparations, and in particular to a device and a process for batch production of refractory slurry and uninterrupted spray feeding thereof. Background Art

[0002] The information described in the Background section is not necessarily admitted to be prior art.

[0003] Tundishes and ladles are intermediate holding vessels used for processing metals and metal alloys. These vessels contain permanent refractory lining materials that are resistant to high temperatures. Typically, these permanent linings are formed of bricks or castables and contain 50% to 70% Al2O3. Although these permanent lining materials are very resistant to high temperatures, their contact with molten metal and slag and the large number of heating and cooling cycles during the processing of molten metal can cause the permanent lining to deteriorate, thus requiring frequent replacement of the permanent lining. Therefore, disposable linings formed of dry vibrable, spreadable, sprayable or sprayable refractory materials are formed over the permanent lining of the tundish or other molten metal processing vessel to extend the service life of the permanent lining.

[0004] In the spraying process of feeding the refractory formulation to the permanent lining, the refractory powder is mixed with water and additives such as binders, wetting agents and dispersants to produce a slurry. The slurry is conveyed under pressure to the spray nozzle, where compressed air is introduced to propel the slurry from the nozzle. The spraying process accommodates uniform mixing because the mixing occurs before the components reach the nozzle and the mixing time is not limited by the contact time of the two components in the spray nozzle.

[0005] The mixing of water and refractory powder can be completed in batch process, in which a predetermined amount of water and refractory powder are contained in a container and programs such as stirring are carried out. Batch process is easy to control processing conditions, such as stirring intensity, the energy introduced into the sample by stirring and the amount of air entrained in the sample. The mixing of water and refractory powder can also be completed in a continuous process, in which water and refractory powder are introduced into the container inlet, and as water and refractory powder pass through the container to arrive at the container outlet, water and refractory powder are merged and processed. However, it is difficult to control process conditions in a continuous process. Although the feeding rate of slurry may change and may be interrupted due to various reasons, the spraying process is a continuous process to a great extent. The demand for slurry is not constant in the feeding process. However, the spraying process depends on the continuous supply of slurry.

[0006] It has been found that properties such as density and porosity of certain sprayed refractory formulations depend on factors such as the presence of additives such as foaming agents in the slurry, combined with the intensity of agitation of the slurry, and the length of time that agitation of the slurry occurs. These factors are more easily controlled in a batch process than in a continuous process, but the need to produce a continuous batch of slurry to feed the spray nozzles necessitates that the slurry consumption rate and amount of slurry available must be monitored so that slurry mixing can be controlled if batch mixing is used.

[0007] WO 199711802 to Daussan discloses a method and apparatus for producing and spraying an aqueous slurry. The aqueous slurry is mechanically agitated to foam and / or expand the surfactant, and the agitation power and / or speed and / or time are adjusted to control the foaming and / or expansion rate of the surfactant and thereby vary the porosity of the sprayed coating. However, there is no disclosure of a method or apparatus in which the start of a batch process feeding a continuous loading process is controlled by data generated by a sensor on a storage container directly feeding the feeder, so that a constant supply of slurry can be produced.

[0008] US 4298288 to Weisbrod discloses a mobile concrete placing method and apparatus in which a plurality of ingredients are fed in a controlled manner into a mixing device to produce a slurry. The slurry is delivered from the mixing device to a nozzle and from there to the surface to be coated. However, the method of Weisbrod is not a batch process; the apparatus of Weisbrod is not configured for batch processing. Thus, there is no disclosure of a method or apparatus in which the start of a batch process feeding a continuous loading process is controlled by data generated by sensors on a storage container that feeds the loader directly, so that a constant supply of slurry can be produced.

[0009] EP 0286513 A1 ((DAUSSAN & CO [FR]) October 12, 1988 (1988-10-12)) relates to a method and apparatus for applying an insulating refractory coating to surfaces, such as the interior of a metallurgical vessel, the insulating refractory coating comprising at least two layers of equal or different thickness, different composition, and equal or different water content. The apparatus comprises: a powder silo; a valve to allow or prevent the flow of material from the powder silo; a mixing member to receive material from the powder silo and water; a product container to receive material from the mixing member; a sensor in which the content or level of the mixed material is sensed; a controller to at least adjust the amount of water in the mixture; and a nozzle to apply the mixture. This apparatus can produce a formulation with a preselected density by varying the amount of components admitted to the batch process, but cannot control the mixing energy introduced into the batch process within a limited time to produce the formulation with the preselected density.

[0010] DE 4217373 A1 (KLAUS OBERMANN GMBH [Germany]) December 16, 1993 (1993-12-16) discloses a device for preparing a mixture or suspension containing a liquid component (e.g., a water-cement mixture, a water-bentonite suspension, etc.), the device having a mixer, which is fed with a certain amount of liquid and solid (powder, granulate, paste or slurry) components from separate supply sources, and a pump is arranged downstream of the mixer for conveying the final mixture into a pipeline leading to a supply container or consumer. The mixer is a continuous mixer that is continuously fed with liquid and solid components, the amount of which corresponds to the final mixture discharged via the pump. The device is not configured to include a batch process, wherein, for example, a controlled amount of mixing energy can be introduced into the batch process within a defined period of time.

[0011] It would therefore be advantageous to develop an apparatus and method which would be advantageous in terms of the combination of components of a sprayable refractory formulation for both batch and continuous processes and would enable the continuous production of products which could achieve a variety of density values ​​using a single formulation. Summary of the invention

[0012] The invention described in this specification relates to an apparatus and a process for batch production of refractory slurry and its uninterrupted spray feeding.

[0013] Exemplary equipment of the present invention includes a batch reactor configured to mix the components of a formulation to produce a refractory slurry. The batch reactor is connected to a plurality of filling inlets. The material flow through or through each reactor filling inlet is regulated by an actuator, which controls, for example, a pump, a feeder or a valve installed in the corresponding inlet. Through the corresponding actuator, the filling inlet is connected between the corresponding feed line or storage container and the batch reactor. The batch reactor is equipped with a reactor outlet, which feeds the contents in the reactor container into a product container when positioned and opened. The product container is equipped with a product container outlet, and the contents of the product container can pass through the product container outlet.

[0014] The product container outlet is in fluid communication with a feeder pump, which is in fluid communication with the feeder through the feeder product inlet. An air supply inlet is also in communication with the feeder, and the air flow through the air supply inlet is regulated by an air supply valve. Within the feeder, the air supply inlet merges with the product inlet to form an outlet, which passes through the feeder nozzle.

[0015] The controller receives information input from the human-machine interface and sensors. The product quantity sensor provides the controller with the measured value of the product quantity in the product container. The flow rate sensor provides the measured value of the flow rate through the air supply inlet and the product inlet. The controller controls the actuator to regulate the product flowing through or passing through the reactor filling inlet. The controller controls the actuator to regulate the start, stop and speed or intensity of processes such as mixing in the batch reactor. The controller controls the actuator fixed to the batch reactor outlet, which regulates the opening and closing of the batch reactor outlet. The controller controls the feeder pump actuator connected to the feeder pump, which starts, stops or adjusts the product delivery rate through the actuator pump. The air supply inlet actuator starts, stops or adjusts the air flow through the air supply inlet.

[0016] The process of loading refractory formulation according to the present invention is performed in the following manner: a filling inlet is set to accept formulation components to enter the batch reactor. Information is input into the controller, the information including batch formulation, batch mixing time and speed. The controller controls the actuator to allow formulation components to enter the batch reactor. The controller controls the actuator to start batch production, adjust batch production and stop batch production after these processes are completed. When batch production is completed, the controller accepts input from the product container amount sensor and determines whether the contents of the batch reactor can be accommodated in the product container. If the contents in the batch reactor can be accommodated in the product container, the controller sends a signal to the actuator to open the outlet of the batch reactor, and the processed batch material is transported to the product container and can be transferred to the nozzle by a slurry pump. At this time, spraying can be started, and the processing of a new batch of materials can be started.

[0017] A continuous supply of a batch-produced preparation can be maintained as follows:

[0018] The controller maintains or collects information regarding the on / off status of the slurry pump, whether batch material is present in the batch reactor, the batch material size in the batch reactor, the on / off status of the batch reactor drive, the remaining mixing time of the batch material in the batch reactor, the amount of slurry in the product container, and whether the batch production and continuous loading equipment is being initialized (i.e., the product container has been partially or fully filled with slurry before spraying begins).

[0019] If the equipment is not initialized and if the slurry pump is not pumping, a new batch will not be started.

[0020] If the slurry pump is pumping, the amount of slurry in the product container is monitored periodically and the capacity of the product container is derived. The capacity of the product container is the amount of slurry that can be accepted from the batch reactor; this is obtained by subtracting the amount of slurry in the product container from the amount of slurry that the batch reactor can accept when the product container is empty. The capacity of the product container is compared with the amount of slurry in the batch reactor. The controller performs actions based on the comparison of the capacity in the product container (AA) and the amount of slurry in the batch reactor (BR), the presence / absence of batch material in the batch reactor (Y / N), the on / off state of the batch reactor driver (BRD), and the remaining mixing time (RMT) of the batch in the batch reactor.

[0021] For the case where AA>BR, BR:N, and BRD OFF, the formulation components are allowed to enter the batch reactor and the BRD is turned ON to begin batch processing. The case where AA>BR, BR:N, and BRD:ON does not occur in normal operation.

[0022] For the case where AA>BR, BR:Y, BRD OFF, and RMT>0, BRD is turned ON to complete the batch process. At the completion of the batch process, BRD is turned OFF and the processed batch is discharged from the batch reactor.

[0023] For the case where AA>BR, BR:Y, BRD ON, and RMT>0, BRD remains ON until the batch processing is complete, at which time BRD is turned OFF and the processed batch is discharged from the batch reactor.

[0024] For the case where AA>BR, BR:Y, BRD ON, and RMT=0, BRD is turned OFF and the processed batch is discharged from the batch reactor.

[0025] For the case where AA > BR, BR: Y, BRD OFF, and RMT = 0, the processed batch is discharged from the batch reactor.

[0026] For the case where AA < BR, BR: N, and BRD OFF, no action is taken until AA > BR. The case where AA < BR, BR: N, and BRD ON does not occur during normal operation.

[0027] For the case where AA < BR, BR: Y, BRD ON, and RMT > 0, BRD is turned OFF until AA > BR.

[0028] For the case where AA < BR, BR: Y, BRD OFF, and RMT > 0, BRD remains OFF until AA > BR.

[0029] For the case where AA < BR, BR: Y, BRD ON, and RMT = 0, BRD is turned OFF and the processed batch is retained in the batch reactor.

[0030] For the case where AA < BR, BR: Y, BRD OFF, and RMT = 0, BRD remains OFF and the processed batch is retained in the batch reactor.

[0031] Aspects of the present invention include, but are not limited to, the following.

[0032] According to one aspect of the present application, a batch production and continuous loading device is provided, comprising: a powder silo having an outlet; a powder feed valve located at the outlet of the powder silo; a powder feed valve regulator connected to the powder feed valve in a controlled manner; a batch reactor, comprising an inlet, a door, a batch reactor driver, a mixing assembly, a batch reactor driver regulator, and a batch reactor door actuator; wherein the outlet of the powder silo is connected to the inlet of the batch reactor; wherein the batch reactor driver regulator is connected to the batch reactor driver in a controlled manner; wherein the batch reactor driver is mechanically connected to the mixing assembly; and wherein the batch reactor door actuator is connected to the door in a controlled manner; a product container having an inlet and an outlet, wherein the inlet of the product container is configured to receive the contents of the batch reactor passing through the door ; a product container contents sensor, connected to the product container in a manner to sense the amount of its contents; a controller, including a data processor / storage unit; wherein the data processor / storage unit is connected to the product container contents sensor in a receiving manner, wherein the data processor / storage unit is connected to the powder feed valve regulator in a controlling manner; wherein the data processor / storage unit is connected to the batch reactor driver regulator in a controlling manner; and wherein the data processor / storage unit is connected to the batch reactor door actuator in a controlling manner; a nozzle, having an inlet and an outlet, wherein the nozzle inlet receives the output of the outlet of the product container; wherein the nozzle inlet receives the output of the air hose; and wherein the flow of air in the air hose is regulated by the air supply valve and controlled by the air supply valve actuator.

[0033] In some embodiments, the batch production and continuous loading equipment further includes: a powder feeder, including an inlet and an outlet, wherein the outlet of the powder bin is connected to the inlet of the powder feeder, wherein the outlet of the powder feeder is connected to the inlet of the batch reactor; and a powder feeder regulator, wherein the powder feeder regulator is connected to the powder feeder in a controlled manner; and wherein the data processor / storage unit is connected to the powder feeder regulator in a controlled manner.

[0034] In some embodiments, the batch production and continuous loading equipment further includes: a slurry pump, including an inlet and an outlet, wherein the inlet of the slurry pump is connected to the outlet of the product container; wherein the outlet of the slurry pump is connected to the inlet of the nozzle; and a slurry pump regulator; wherein the slurry pump regulator is connected to the slurry pump in a controlled manner; wherein the data processor / storage unit is connected to the slurry pump regulator in a controlled manner.

[0035] In some embodiments, the batch production and continuous loading equipment further includes: a water valve; a water supply pipe, wherein the water supply pipe extends through the water valve to reach the batch reactor water inlet of the batch reactor; and a water valve actuator; wherein the water valve actuator is connected to the water valve in a controlled manner, and wherein the data processor / storage unit is connected to the water valve actuator in a controlled manner.

[0036] In some embodiments, the batch production and continuous loading equipment further comprises: a water flow sensor connected to the water supply pipe in a sensing manner, wherein the data processor / storage unit is connected to the water flow sensor in a receiving manner.

[0037] Optionally, a batch production and continuous loading device as described above, wherein the data processor / storage unit is configured to process data received from the product container content sensor to control the powder feed valve regulator, the water valve actuator and the batch reactor drive regulator.

[0038] In some embodiments, the batch production and continuous loading equipment further comprises: a load measurement sensor in sensing communication with the batch reactor, wherein the data processor / storage unit is in receiving communication with the load measurement sensor.

[0039] In some embodiments, the batch production and continuous loading equipment further includes: a powder silo vibration device, connected to the powder silo, and a powder silo vibration device actuator; wherein the powder silo vibration device actuator is connected to the powder silo vibration device in a controlled manner; a product container vibration device, connected to the product container, and a product container vibration actuator, wherein the product container vibration actuator is connected to the product container vibration device in a controlled manner.

[0040] Optionally, a batch production and continuous loading apparatus as described above, wherein the data processor / data storage unit is configured to generate a ratio of the flow rate through the slurry pump to the flow rate through the air hose, and is configured to maintain the ratio of the slurry pump flow rate to the air hose flow rate when the air hose flow rate changes.

[0041] Optionally, the batch production and continuous feeding apparatus as described above, wherein the batch reactor drive is configured to supply at least 7500 watts of mechanical power to the mixing assembly.

[0042] According to another aspect of the present application, a method for batch production and continuous feeding of refractory formulations is provided, comprising: (a) providing any of the batch production and continuous feeding equipment described above; (b) providing instructions to a controller; (c) using a data processor / storage unit, a powder feed valve regulator and a powder feed valve, and data from a product container content sensor to control the delivery of powder from a powder silo to a batch reactor to fill the batch reactor; (d) using a data processor / storage unit, a batch reactor driver regulator, a batch reactor driver, and data from a product container content sensor to control the delivery of powder from a powder silo to a batch reactor to fill the batch reactor; (e) utilizing a data processor / storage unit, a batch reactor door actuator and a batch reactor door and data from a product container content sensor to feed the product from the batch reactor into the product container; (f) conveying the product from the product container to a nozzle; (g) providing air to the nozzle; (h) mixing the product with the air in the nozzle; (i) spraying the mixed air and product; and (j) repeating steps (c), (d) and (e) to produce a continuous supply of the product.

[0043] Optionally, a method for batch production and continuous loading of refractory formulations as described above, wherein the batch processing and continuous loading equipment further includes a water supply pipe, a water valve and a water valve actuator, wherein the batch reactor further includes a water inlet for the batch reactor; wherein the water supply pipe extends through the water valve to reach the water inlet for the batch reactor; wherein the water valve actuator is connected to the water valve in a controlled manner, and wherein the data processor / storage unit is connected to the water valve actuator in a controlled manner; and wherein step (c) further includes: (c') utilizing the data processor / storage unit, the water valve actuator, the water valve and data from the product container contents sensor to control the input of water into the batch reactor.

[0044] Optionally, a method for batch production and continuous loading of refractory formulations as described above, wherein, if the data processor / storage unit determines that the batch reactor is not filled and the product container is capable of accommodating the product to be produced by the powder and water input into the batch reactor, and at least one of system initialization and spraying is occurring, it is enabled to transport the powder from the powder silo to the batch reactor and to input water into the batch reactor.

[0045] Optionally, the method for batch production and continuous feeding of refractory formulations as described above, wherein the batch processing and continuous feeding equipment further includes: a slurry pump, including an inlet and an outlet; wherein the equipment further includes a slurry pump regulator; wherein the inlet of the slurry pump is connected to the outlet of the product container; wherein the outlet of the slurry pump is connected to the inlet of the nozzle; and wherein the slurry pump regulator is connected to the slurry pump in a controlled manner; wherein the data processor / storage unit is connected to the slurry pump regulator in a controlled manner; and wherein step (d) includes: if the data processor / storage unit determines that the slurry pump has been started , the batch reactor has been filled and the product container can accommodate the contents of the batch reactor, start the mixing component; if the batch reactor has been filled and the product container can accommodate the contents of the batch reactor, start the mixing component during system initialization; if the data processor / storage unit determines that the slurry pump has been started, the batch reactor has been filled, and the product container cannot accommodate the contents of the batch reactor, pause the mixing component; if the data processor / storage unit determines that batch processing is complete, deactivate the mixing component; if the data processor / storage unit determines that the slurry pump is deactivated, deactivate the mixing component.

[0046] Optionally, a method for batch production and continuous loading of refractory formulations as described above, wherein the batch processing and continuous loading equipment further includes: a load measuring sensor, which is connected to the batch reactor in a sensing manner, wherein the data processor / storage unit is connected to the load measuring sensor in a receiving manner; and wherein data from the load measuring sensor is used to control the delivery of powder from the powder silo to the batch reactor to fill the batch reactor, and to control the supply of water to the batch reactor. BRIEF DESCRIPTION OF THE DRAWINGS

[0047] The various features and characteristics of the present invention described in this specification may be more fully understood by referring to the accompanying drawings, in which:

[0048] FIG. 1( a ) is a schematic diagram of a refractory slurry production and feeding equipment;

[0049] FIG. 1( b ) is a schematic diagram of a controller for a batch production and continuous feeding device; and

[0050] Figure 2 It is a schematic diagram of the data acquisition and control elements of the refractory slurry production and feeding equipment.

[0051] The reader will appreciate the foregoing features and characteristics, as well as others, after considering the following detailed description of the invention. DETAILED DESCRIPTION

[0052] The refractory compositions described in this specification produce working linings or other refractory structures that provide anti-oxidative barrier properties during use in metallurgical vessels. As used in this specification (including the claims), the term "working lining" refers to the innermost refractory layer in contact with the molten metal contained in the metallurgical vessel. As used in this specification (including the claims), the term "metal" refers to both metals and metal alloys. As used in this specification, the expression "communicating with ... in a receiving manner" is used to describe that a device or an element of a device receives data (such as data in electronic form) sent from another device or an element of a device. As used in this specification, the expression "communicating with ... in a sensing manner" is used to describe that a device or an element of a device measures, analyzes or otherwise obtains information from another device, an element of a device, the contents of a device or a sample of material. As used in this specification, the expression "communicating with ... in a controlling manner" is used to describe that a device or an element of a device transmits a command to another device or an element of a device. As used in this specification, the expression "communicating with ... in a controlling manner" is used to describe that a device or an element of a device transmits a command to another device or an element of a device. As used in this specification, the expression "communicating with ... in a receiving manner" is used to describe indirect contact through an intermediate element or direct contact without an intermediate element.

[0053] FIG. 1( a) is a schematic diagram of the construction of a batch production and continuous loading apparatus 2 including a batch reactor 10. The batch reactor 10 is equipped with a powder feed port 12 and a water inlet port 14. The batch reactor 10 is equipped with a batch reactor drive 16, which is attached to, mechanically connected to, and capable of moving a mixing assembly 17, which may include mixing, blending, stirring or agitating elements such as paddles and blades within the batch reactor 10. The batch reactor drive 16 is regulated by a batch reactor drive regulator 18; the batch reactor drive regulator 18 is connected to the batch reactor drive 16 in a control manner. The batch reactor drive regulator 18 can start, stop or change the speed of the mixing assembly 17 within the batch reactor 10. The load measurement sensor 20 provides a weight measurement of the contents of the batch reactor 10. The load measurement sensor 20 is connected to the batch reactor 10 in a sensing manner.

[0054] The contents of the batch reactor are removed through a batch reactor door 22, which is regulated by a batch reactor door actuator 24; the batch reactor door actuator 24 opens and closes the batch reactor door 22. The batch reactor door 22 constitutes an outlet of the batch reactor 10. The batch reactor door actuator 24 is in control communication with the door 22. A five-port-two-way directional valve in communication with the batch reactor door actuator 24 can be used to operate the batch reactor door 22.

[0055] The powder silo 30 is equipped with a powder silo vibration device 32 regulated by a powder silo vibration actuator 34. The powder silo vibration device 32 can be attached to the powder silo 30, or can be communicated with the powder silo 30. The powder silo vibration device actuator 34 is communicated with the powder silo vibration device 32 in a controlled manner. Through the powder feed valve 38 regulated by the powder feed valve regulator 40, the powder is fed from the powder silo 30 to the inlet of a powder feeder 42, which has an inlet and an outlet, includes a motor, and includes material conveying devices such as screw or spiral. The powder feeder 42 is controlled by a powder feeder regulator 44. The powder feeder regulator 44 enables a selected amount of powder to be transported to the batch reactor 10. The measured values ​​from the load measurement sensor 20 are processed and the processed measured values ​​are provided to the powder feeder regulator 44 to charge the batch reactor 10 with a predetermined amount of powder. The powder leaving the powder feeder 42 is fed to the powder feed port 12 of the batch reactor 10. A five-port two-way directional valve may be used as the powder feed valve 38. The powder feed valve 38 and the powder feed valve regulator 40 may be integrally formed. The powder silo 30 has an outlet; the powder feed valve 38 may be located at or near the powder silo outlet; the powder feed valve regulator 40 is in controlled communication with the powder feed valve 38. The outlet of the powder silo 30 is in communication with the inlet of the batch reactor.

[0056] The water supply line 50 passes through or through a water flow sensor 52 and through a water valve 54 controlled by a water valve actuator 56 to enter the water inlet 14 of the batch reactor 10. The water valve actuator 56 is capable of delivering a selected amount of water to the batch reactor 10. The water valve actuator 56 is in control communication with the water valve 54. The water flow sensor 52 is in sensing communication with the water supply pipe 50. The water flow sensor 52 may include a hydrodynamic rotor and a Hall effect sensor.

[0057] After mixing, the contents of the batch reactor 10 are fed into a product container 60 through a batch reactor door 22. The product container 60 has an inlet and an outlet; the inlet of the product container 60 is configured to receive the contents of the batch reactor 10 through the door 22. In the illustrated configuration, the door 22 is located above the inlet of the product container 60, and the contents of the batch reactor 10 fall into the product container 60 after passing through the door 22. The product container 60 is equipped with a product tank vibration device 62 regulated by a product container vibration actuator 64. The product container vibration device 62 can be attached to the product container 60, or can be in communication with the product container 60. The product container vibration actuator 64 is in control communication with the product container vibration device 62. The product container 60 is equipped with a product container measurement sensor 66 for measuring the amount of slurry 68 within the product container 60. The product container content sensor 66 is in sensing communication with the contents 68 of the product container 60. The product container 60 can have a lower portion in the shape of a truncated cone head, with its smallest radius located near the outlet of the product container 60.

[0058] The contents of the product container 60 are fed into the inlet of a slurry pump 70. The slurry pump 70 has an inlet and an outlet. The inlet of the slurry pump 70 is directly or indirectly connected to the outlet of the product container 60. The slurry pump 70 includes a motor and a material conveying structure such as a screw. The slurry pump 70 is regulated by a slurry pump regulator 72. The slurry pump regulator 72 is connected to the slurry pump 70 in a controlled manner.

[0059] The output of the slurry pump 70 is pushed through the slurry hose 76 to the nozzle 80. The outlet of the slurry pump 70 is in communication with the inlet of the nozzle 80.

[0060] Air passes through air hose 86, through air supply valve 88 regulated by air supply valve actuator 90, and past or through air flow sensor 92 to nozzle 80. Air flow sensor 92 may be an analog device or a digital device.

[0061] In the nozzle 80, air is injected into the slurry flow just before the discharge point. The slurry is propelled from the discharge point of the nozzle 80. The nozzle 80 has an inlet and an outlet. The nozzle inlet receives the output of the outlet of the product container 60; the nozzle inlet receives the output of the air hose 86. The nozzle inlet can be divided into separate chambers, including a chamber for receiving the output of the outlet of the product container 60 and a chamber for receiving the output of the air hose 86; in this configuration, the product container chamber and the air chamber merge in the nozzle 80 to communicate with the nozzle outlet. The air flow in the air hose 86 is regulated by the air supply valve 88 and controlled by the air supply valve actuator 90.

[0062] FIG1( b) is a schematic diagram of a controller 100 of a batch production and continuous feeding device 2. The control of the batch production and continuous feeding device 2 is achieved by the controller 100, which includes a controller human-machine interface (HMI) display 102, a control panel 104, a command transmission port 106, a data acquisition port 108, and a processor 112. The human-machine interface display 102 is a device that allows interaction between humans and machines; it can accept and execute operator control instructions and can display process status information to the operator. The control panel 104 is a surface that can include manual controls such as switches, buttons, knobs, or keyboards for device operation, and can include display components such as meters and video screens for providing device status information.

[0063] Figure 2 1( b ) is a schematic diagram of a controller 100 and a controller connection 101. The controller includes a human-machine interface display 102 and a control panel 104, which are used to view process data and input commands, respectively. The human-machine interface display 102 and the control panel 104 can be separate devices or integrated devices.

[0064] The controller 100 includes a command transmission port 106. The controller communicates with the batch reactor driver regulator 18, the batch reactor door actuator 24, the powder silo vibration actuator 34, the powder feed valve regulator 40, the powder feeder regulator 44, the water valve actuator 56, the product container vibration actuator 64, the slurry pump regulator 72, and the air supply valve actuator 90 through the command transmission port 106.

[0065] The controller 100 includes a data acquisition port 108. The controller communicates with the load measurement sensor 20, the water flow sensor 52, the product container measurement sensor 66, and the air flow sensor 92 through the data acquisition port 108.

[0066] The controller 100 includes a data processor / data storage unit 112, which receives data input from the human-machine interface display 102, the control panel 104, the load measurement sensor 20, the water flow sensor 52, the product container measurement sensor 66, and the air flow sensor 92 and communicates with the above components in a receiving manner. The data processor / data storage unit 112 performs calculations and logical operations on the data provided from the interface 102, the control panel 104, the sensors 20, 52, 66, and 92 and the internally stored data. Commands based on the results of the calculations and logical operations are issued to the regulators and actuators 18, 24, 34, 40, 44, 56, 64, 72, and 90 through the command transmission port. The data processor / data storage unit 112 communicates with the regulators and actuators 18, 24, 34, 40, 44, 56, 64, 72, and 90 in a control manner.

[0067] The connection between the controller and the various actuators and sensors may be established by wires, fiber optic cables or by wireless transmission 101. The devices may communicate via Ethernet / IP.

[0068] Specialized elements may be used in the devices described herein.

[0069] The batch reactor 10 can take the form of a closed container equipped with an internal mixing assembly that is configured to mix the contents of the batch reactor 10. The batch reactor 10 can be equipped with a batch reactor drive 16 (e.g., a 7500 watt gear motor connected to a variable frequency drive) and a mixing assembly 17 that can include mixing blades (e.g., batch reactor angular slurry whipping mixing blades) connected to a rotating shaft driven by the batch reactor drive 16. The batch reactor 10 can take the form of a barrel paddle mixer. The batch reactor 10 formed by a 0.25 cubic meter slurry holding barrel will accommodate 90 kg batches of refractory slurry. A pneumatic piston can be used as a batch reactor door actuator 24. The batch reactor door 22 is typically located at the bottom of the batch reactor 10. The product container 60 can be located below the batch reactor door 22 so that the completed batch can be poured from the batch reactor 10 into the product container 60. In the presence of powder and water, the mixer blades rotate at a defined speed and time controlled by the process as indicated by the operator set point. By introducing low or high shear forces and enhanced mixing energy into the batch process within a defined time period, the physical properties of the slurry can be changed to the desired results. The power of the motor may be 7500 watts or more; it has been found that a motor power of 7500 watts or more is required to reduce the density of the refractory batch material. The batch reactor drive 16 can be configured to supply at least 7500 watts of mechanical power to the mixing assembly 17.

[0070] The load measuring sensor 20 may be a load cell system such as a hydraulic load cell, a pneumatic load cell or a strain gauge load cell. A system with a capacity of 9000 kg may be used.

[0071] The powder silo vibration device 32 regulated by the powder silo vibration actuator 34 can be used together with the powder silo 30 to eliminate bridging, material jamming and uneven flow. The powder silo vibration device 32 can be electric or pneumatic. Usually, the powder silo vibration device 32 is in physical contact or communication with the powder silo 30. The 1800kg storage silo may be suitable for use as the powder silo 30 in batch production and continuous feeding equipment 2.

[0072] The powder feeder 42 may comprise a motor, such as a 750 watt electric gear motor connected to a variable frequency drive. The feeding of the powder may be accomplished by a conveyor such as a 10 cm spiral screw.

[0073] The water valve actuator 56 for the water valve 54 may be a bi-directional fluid solenoid.

[0074] The slurry level measurement sensor 66 can be a laser distance sensor. The sensor can be arranged in or above the product container 60. The sensor can be arranged toward the discharge port of the product container 60.

[0075] The slurry pump 70 may include a motor, such as a 9300 watt electric gear motor connected to a variable frequency drive. The slurry pump 70 may also include a hopper-type paddle feeder and a rotor-stator assembly, and a vibrating air motor. A slurry holding hopper having a volume of 0.17 cubic meters may be provided to receive slurry from the product container 60. When this configuration is in operation and slurry is present, the pump rotates at a variable speed to feed slurry from the holding hopper using the paddle feeder, forcing the slurry into the rotor-stator assembly, where the slurry is uniformly extruded through the pump discharge outlet. The vibrating air motor flattens the slurry in the slurry hopper so that the container measurement sensor 66 obtains an accurate measurement of the slurry amount 68 in the product container 60.

[0076] In a typical configuration, the spray nozzle 80 comprises a 30 cm x 2.5 cm diameter hydraulic hose section connected to a cast aluminum nozzle tip with an integral atomizing air tube and a 12 mm atomizing rubber nozzle cap. As the slurry is pumped to the nozzle, low-compression air is injected into the slurry stream just before the discharge point (a 12 mm hole concentric with the atomizing air tube). This action forms a conical pattern of slurry, which is then applied to the surface.

[0077] The air supply valve actuator 90 for the air supply valve 88 may be a bi-directional fluid solenoid.

[0078] Machine control may be achieved by using an Allen Bradley Micrologixs 1400 PLC controller as controller 100 and a C-More HMI display as HMI display 102. A HMI display is a screen that allows a user to interact with equipment, such as equipment that performs or controls an industrial process.

[0079] Formulations that may be used with the disclosed apparatus include alumina formulations containing calcium aluminate cement and dispersants.While batch and continuous feed equipment can produce refractory slurries having a range of densities from a single component mixture, it is also capable of producing continuous batches of refractory slurries having varying water contents.

[0080] The batch production and continuous loading apparatus 2 can be configured to prevent the generation of excessive slurry. If the product container 60 cannot be kept in contact with the batch reactor 10, the product container measurement sensor 66 identifies the excessive slurry in the product container 60 (e.g., by providing information to the data processor / storage unit 112 for determining that the product container 60 cannot accommodate the contents of the batch reactor 10), and the data processor / storage unit 112 places the batch reactor 10 in a "hold" state until enough slurry has been discharged from the product container 60 so that additional batch material can be discharged from the batch reactor 10 and completely contained in the product container 60. The "hold" state can include suspending the mixing process and / or suspending the transfer of slurry from the batch reactor 10 to the product container 60. This can be accomplished in a configuration of the apparatus 2 in which the data processor / storage unit 112 is configured to process data received from the product container content sensor 66 to control the batch reactor drive regulator 18 and the batch reactor door actuator 24.

[0081] The batch production and continuous loading apparatus 2 can also be configured such that if the product container 60 cannot be aligned with the batch reactor 10, the product container measurement sensor 66 identifies excessive slurry in the product container 60 (e.g., by providing information to the data processor / storage unit 112 for determining that the product container 60 cannot accommodate the contents of the batch reactor 10), and the data processor / storage unit 112 will stop the delivery of powder, water and other formulation components to the batch reactor 10 until sufficient slurry has been removed from the product container 60 so that additional batch material can be discharged from the batch reactor 10 and the additional batch material is completely contained in the product tank 60. This can be achieved in a configuration of the apparatus 2 in which the data processor / storage unit 112 is configured to process data received from the product container content sensor 66 to control the powder feed valve regulator 40, the water valve actuator 56 and the batch reactor drive regulator 18. The data processor / storage unit can also process data received from the product container content sensor 66 to control the batch reactor door actuator 24.

[0082] The batch production and continuous loading equipment 2 can also be configured to prevent interruption of the loading process due to lack of slurry in the product container 60. In one configuration, if the product container measurement sensor 66 detects that the slurry in the product container 60 is a predetermined minimum amount or low level, a signal is sent to the controller human-machine interface display 102. The operator then reduces the maximum speed (rpm) of the slurry pump 70. In another configuration, if the product container measurement sensor 66 detects that the slurry level in the product container 60 is low, the data processor / data storage unit 112 performs calculations based on the accumulated slurry usage rate (S / T), based on data obtained from the amount (S) of slurry 68 in the product container 60 and the remaining mixing time (RMT) of the batch in the batch reactor 10. If (S / T)>(S / (RMT)), the slurry pump regulator 72 reduces the maximum slurry usage rate to less than (S / (RMT)).

[0083] In terms of structure, the outlet of the powder silo 30 is connected to the inlet of the powder feed valve 38. The outlet of the powder feed valve 38 is connected to the inlet of the powder feeder 42. The outlet of the powder feeder 42 is connected to the batch reactor powder feed port 12 of the batch reactor 10. The water supply pipe 50 extends from the water source through the water valve 54 to the batch reactor water inlet 14. The outlet of the batch reactor 10 is connected to the inlet of the product container 60. The outlet of the product tank 60 is connected to the input of the slurry pump 70. The outlet of the slurry pump 70 is connected to an inlet or the inlet of the nozzle 80. The air supply line extends from the compressed air source through the air supply valve 88 and the air hose 86 to an inlet or the inlet of the nozzle 80. The air from the air hose 86 is mixed with the product or content of the slurry hose 76 in the nozzle 80 and sprayed out from the nozzle 80.

[0084] The method of producing a refractory composition using a batch production and continuous loading device 2 and continuously loading the refractory composition onto a surface is performed as follows: dry formulation components are introduced into a powder silo 30. The powder silo vibration device 32 can be activated by a powder silo vibration device actuator, which can be controlled by the data processor / data storage unit 112 of the controller 100 via the command transmission port 106. The operator inputs batch production settings and instructions (such as batch size, moisture content, dry component content, mixing time and mixing speed, and commands to start batch production) into the controller 100 through the controller human-machine interface display 102, control panel 104 or other input devices. The controller 100 transmits commands to the powder feed valve regulator 40 and the powder feed valve 38, and / or to the powder feeder regulator 42 through the command transmission port 106 to transport the dry components from the powder silo 30 to the inlet of the powder feeder 42. The dry components are delivered from the outlet of the powder feeder 42 to the batch reactor powder feed port 12 and into the batch reactor 10. The amount of powder delivered from the powder silo 30 to the batch reactor 10 can be determined by the load measurement sensor 20 by the difference between before and after delivery. Therefore, the data from the load measurement sensor 20 can be used to control the delivery of powder from the powder silo 30 to the batch reactor 10.

[0085] The controller 100 transmits a command to the water valve actuator 56 and the water valve 54 through the command transmission port 106 to introduce water from the water supply pipe 50 into the batch reactor 10. The amount of water delivered to the batch reactor 10 can be obtained by the water flow sensor 52, or determined by the load measurement sensor 20 by the difference between before and after delivery. Therefore, the data from the load measurement sensor 20 can be used to control the supply of water to the batch reactor 10. Additional liquid or dissolved components can be introduced into the water supply pipe 50, or additional liquid or dissolved components can be introduced into the batch reactor 10 from a separate container equipped with a valve and a valve actuator. The controller 100 derives the amount (or mass or density) of the material in the batch reactor 109 from the data provided by the sensor 52 and / or the sensor 20.

[0086] The process of placing batch components into the batch reactor 10 is called "charging". When all batch components enter the batch reactor 10 in selected amounts, the controller 100 transmits a command to the batch reactor driver regulator 18 through the command transmission port to start the batch reactor driver 16 to start the mixing process in the batch reactor 10. The controller 100 regulates the start, end, pause, duration and intensity of the mixing. The controller 100 also calculates and maintains the value of the remaining mixing time. The intensity of the mixing is related to the rotation speed of the mixing structure in the batch reactor 10 and the configuration of the mixing assembly 17 such as a mixing blade or paddle. The batch reactor 10 can include any known type of agitator. The batch size, the mixing duration and the mixing intensity of the combination of the components can be selected based on a calibration table that associates the batch size, the mixing time and the mixing intensity of a specific combination of the components to produce a slurry with a specified density.

[0087] During batch mixing, the controller 100 monitors the contents 68 of the product container 60. The product container contents sensor 66 provides this information to the controller 100 via the data acquisition port 108 so that the amount of product in the product container 60 can be determined by the data processor / data storage unit 112. If the product container 60 cannot accommodate the batch material being mixed, the controller 100 transmits a command to the batch reactor drive actuator 18 to pause batch mixing until the product container 60 can accommodate the batch material. If no batch material is being mixed and the product container 60 cannot accommodate the next batch material to be mixed, the combination of the components and the start of batch mixing are delayed until the product container 60 can accommodate the batch material. Typically, the process vessel 60 accommodates at least two batches produced by the batch reactor 10, so there will be no need to suspend the batch mixing process during the production of the initial batch.

[0088] When the batch mixing is complete and the contents of the batch mixer 10 can be contained by the product container 60, the controller 100 transmits a command to the batch reactor door actuator 24 to open the batch reactor door 22. The contents of the batch mixer 10 are thereby delivered to the product container 60. The product container 60 can be equipped with a product container vibration device 62 that is in communication with the product container vibration actuator 64. The product container vibration device 62 can be electric or pneumatic. The product container vibration device 62 ensures that the slurry remains in contact with the discharge port of the product container 60 and will exit through the discharge port. An indication that there is product in the product container 60 (which can be sensed by the product container content sensor 66) can be received by the controller 100 and used by the data processor / storage unit 112 to convey a command to the product container vibration device actuator 64 to begin operating the product container vibration device 62.

[0089] The portion of the process that occurs before spraying begins can be referred to as system initialization. When there is product in the product container 60, spraying of the slurry can begin. The controller 101 transmits commands to the slurry pump regulator 72 to control the pumping rate of the slurry pump 70 to provide the product or slurry to the nozzle 80, and transmits commands to the air supply valve actuator 90 to control the rate of air flow through the air supply valve 88 and the air hose 86 to provide air to the nozzle 80. The slurry flows from the slurry pump 70 to the nozzle 80 through the slurry hose 76; the air flows to the nozzle 80 through the air hose 86. The air flow sensor 92 transmits flow rate information to the controller 100; the controller 100 transmits commands to the air supply valve actuator 90 of the slurry pump regulator 72 to balance the flow rate through the slurry pump 70 and the air hose 86 so that the slurry is sprayed from the nozzle 80 at the expected pressure. The operator can adjust the pumping rate of the slurry pump 70 at any time during the process by entering a command through the controller human-machine interface display 102 or through the control panel 104, or by manipulating the air supply valve actuator 90; in certain configurations of the device, the pumping rate of the slurry pump 70 is maintained at a set ratio to the rate of air flow through the air supply valve 88. The data processor / data storage unit 112 can be configured to generate a ratio of the flow rate through the slurry pump 70 to the flow rate through the air hose 86, and is configured to maintain the ratio of the slurry pump flow rate to the air hose flow rate when the air hose flow rate changes. The operator can terminate the operation of the slurry pump 70 by entering a "stop" command through the controller human-machine interface display 102 or through the control panel 104, or by manipulating the air supply valve actuator 90; in certain configurations of the device, the slurry pump 70 is shut off when the air flow through the air supply valve 88 is shut off. In certain configurations of the batch production and continuous loading apparatus 2, deactivation of the slurry pump 70 and / or the air supply after system initialization can prevent the start of a batch process in the batch mixer 10. If a new batch cannot be accommodated by the product tank 60, data provided by the product container content sensor 66 can be received by the controller 100 and used by the data processor / storage unit 112 to prevent the start of batch processing in the batch mixer 10, or the introduction of formulation components into the batch mixer 10.

[0090] A process for batch production of a refractory composition using the apparatus described herein and continuous loading of the refractory composition onto a surface may include the following steps:

[0091] (a) Providing batch production and continuous feeding equipment 2;

[0092] (b) Providing instructions to the controller 100.

[0093] (c) controlling the delivery of powder from the powder silo 30 to the batch reactor 10 to fill the batch reactor 10 using the data processor / storage unit 112, the powder feed valve regulator 40 and the powder feed valve 38 and data from the product container content sensor 66;

[0094] (d) utilizing the data processor / storage unit 112, the batch reactor driver regulator 18, the batch reactor driver 16, and data from the product container contents sensor 66 to activate, control, and deactivate the mixing assembly 17 in the batch reactor 10 to process the powder to form the product;

[0095] (e) utilizing the data processor / storage unit 112, the batch reactor door actuator 24 and the batch reactor door 22, and data from the product container contents sensor 66 to advance product from the batch reactor 10 into the product container 60;

[0096] (f) delivering product from product container 60 to nozzle 80;

[0097] (g) supplying air to the nozzle 80;

[0098] (h) mixing the product with air in nozzle 80;

[0099] (h) spraying the mixed air and product; and

[0100] (i) Repeating step (c), step (d) and step (e) to produce a continuous supply of product.

[0101] Step (c) may further include: (c′) controlling the input of water to the batch reactor 10 using the data processor / storage unit 112 , the water valve actuator 56 , the water valve 54 , and data from the product container contents sensor 66 .

[0102] Step (c) may include the following constraints: if the data processor / storage unit 112 determines that the batch reactor 10 is not filled, and the product container (60) is capable of accommodating the product to be produced by the powder and water input into the batch reactor 10, and at least one of system initialization (wherein the product is produced at the beginning of operation before spraying can begin) and spraying occurs, then powder can be transported from the powder silo 30 to the batch reactor 10 and water can be input into the batch reactor 10.

[0103] Step (d) may include:

[0104] If the data processor / storage unit 122 determines that the slurry pump 70 is activated, the batch reactor 10 is primed, and the product container 60 is capable of containing the contents of the batch reactor 10, then the mixing assembly 17 is activated;

[0105] If the batch reactor 10 is primed and the product container 60 is capable of accommodating the contents of the batch reactor 10, the mixing assembly 17 is activated during system initialization;

[0106] If the data processor / storage unit 122 determines that the slurry pump 70 has been activated, the batch reactor 10 has been primed, and the product container 60 cannot accommodate the contents of the batch reactor 10, then the mixing assembly 17 is paused;

[0107] If the data processor / storage unit 122 determines that the batch process is complete, then deactivating the mixing assembly 17; and

[0108] If the data processor / storage unit 122 determines that the slurry pump 70 has been deactivated, the mixing assembly 17 is deactivated.

[0109] Data from the load measurement sensor 20 may be used to control the delivery of powder from the powder silo 30 to the batch reactor 10 , to fill the batch reactor 10 and to control the supply of water to the batch reactor 10 .

[0110] Example

[0111] The batch production and continuous feeding equipment 2 is capable of producing refractory slurries with a range of densities from a single component mixture. A wide range of densities is produced by mixing the components with specific values ​​within a range of mixing time and speed. A calibration table (showing the slurry density produced for various combinations of mixing time, mixing speed and spraying pressure) enables the equipment to be programmed and instructions entered to produce a formulation with a desired density. Example 1:

[0112] The following table shows the experimental results correlating batch reactor mixer speed and agitation time to density based on density drop. The baseline density of this formulation using a conventional continuous mixer was approximately 120 lb / ft 3 (1920kg / m 3 ). The mixture of dry components contains 93% refractory material, 0.25% anionic surfactant and bonding material. The mixture of dry components is mixed with water to produce a slurry containing 20wt% water. Each batch of 200lb (90kg) of mixed dry components is mixed in batches for 7 minutes. Water is then added and each batch is mixed at a time period and speed as shown in Table I. As indicated in the table, the density of the slurry removed from the batch mixer or after spraying is obtained.

[0113] Table 1 Relationship between mixing speed, mixing time and spraying pressure and density

[0114]

[0115]

[0116] element:

[0117] 2. Batch production and continuous feeding equipment

[0118] 10. Batch Reactor

[0119] 12. Batch reactor powder feed port

[0120] 14. Batch reactor water inlet

[0121] 16. Batch Reactor Driver

[0122] 17. Hybrid Components

[0123] 18. Batch Reactor Driver Regulator

[0124] 20. Load measurement sensor

[0125] 22. Batch Reactor Door

[0126] 24. Batch Reactor Door Actuator

[0127] 30. Powder silo

[0128] 32. Powder silo vibration equipment

[0129] 34. Powder silo vibration equipment actuator

[0130] 38. Powder feeding valve

[0131] 40. Powder feed valve regulator

[0132] 42. Powder feeder

[0133] 44. Powder feeder regulator

[0134] 50. Water supply pipe

[0135] 52. Water flow sensor

[0136] 54. Water valve

[0137] 56.Water valve actuator

[0138] 60.Product container

[0139] 62. Product container vibration equipment

[0140] 64.Product container vibration equipment actuator

[0141] 66. Product container content sensor

[0142] 68. Product container contents

[0143] 70. Slurry pump

[0144] 72.Slurry pump regulator

[0145] 76. Slurry hose

[0146] 80. Nozzle

[0147] 86.Air hose

[0148] 88.Air supply valve

[0149] 90.Air supply valve actuator

[0150] 92. Airflow sensor

[0151] 100. Controller

[0152] 101. Controller connector

[0153] 102. Controller human-machine interface display

[0154] 104. Control Panel

[0155] 106. Command transmission port

[0156] 108.Data collection port

[0157] 112.Data processor / data storage unit

[0158] The present invention may include, consist of or substantially consist of the various features and characteristics described in this specification. In some cases, the present invention may also be substantially free of components or other features or characteristics described in this specification.

[0159] In addition, any numerical range stated in this specification includes the stated endpoints and describes all subranges with the same numerical precision (i.e., with the same number of specified digits) contained within the stated range. For example, the stated range "1.0 to 10.0" describes all subranges between (and including) the stated minimum value of 1.0 and the stated maximum value of 10.0, such as "2.4 to 7.6", even if the range of "2.4 to 7.6" is not explicitly stated in the text of the specification. Therefore, the applicant reserves the right to amend this specification (including the claims) to explicitly state any subranges of the same numerical precision contained within the range explicitly stated in this specification. All such ranges are implicitly included in this specification so that amendments to explicitly state any such subranges will comply with the written description, sufficiency of description, and addition requirements (e.g., 35 U.S.C. §112(a) and 123(2) EPC).

[0160] The grammatical articles "one," "a," "an," and "the," as used in this specification, are intended to include "at least one" or "one or more," unless the context indicates or requires otherwise. Thus, the articles used in this specification refer to one or more of the grammatical object of the article (i.e., "at least one"). By way of example, "a component" refers to one or more components, and thus, more than one component is contemplated and may be employed or used in the practice of the invention. Furthermore, use of a singular noun includes the plural, and use of a plural noun includes the singular, unless the context of use requires otherwise.

Claims

1. A batch production and continuous feeding device (2), comprising: A powder bin (30) having an outlet; A powder feeding valve (38) is located at the outlet of the powder bin; a powder feed valve regulator (40) connected to the powder feed valve (38) in a controlled manner; A batch reactor (10) comprising an inlet, a door (22), a batch reactor driver (16), a mixing assembly (17), a batch reactor driver regulator (18) and a batch reactor door actuator (24); wherein the outlet of the powder silo (30) is in communication with the inlet of the batch reactor; wherein the batch reactor driver regulator (18) is in controllable communication with the batch reactor driver (16); wherein the batch reactor driver (16) is in mechanical communication with the mixing assembly (17); and wherein the batch reactor door actuator (24) is in controllable communication with the door (22); a product container (60) having an inlet and an outlet, wherein the inlet of the product container (60) is configured to receive contents of the batch reactor (10) through the door (22); a product container contents sensor (66) in sensing communication with the amount of contents (68) of the product container (60); A controller (100) comprising a data processor / storage unit (112); wherein the data processor / storage unit (112) is in receiving communication with the product container content sensor (66), wherein the data processor / storage unit (112) is in controlling communication with the powder feed valve regulator (40); wherein the data processor / storage unit (112) is in controlling communication with the batch reactor driver regulator (18); and wherein the data processor / storage unit (112) is in controlling communication with the batch reactor door actuator (24); a nozzle (80) having an inlet and an outlet, wherein the nozzle inlet receives the output of the outlet of the product container (60); wherein the nozzle inlet receives the output of an air hose (86); and wherein the flow of air in the air hose (86) is regulated by an air supply valve (88) and controlled by an air supply valve actuator (90), Water valve (54); a water supply pipe (50), wherein the water supply pipe (50) extends through a water valve (54) to a batch reactor water inlet of the batch reactor (10); and A water valve actuator (56); wherein the water valve actuator (56) is in control communication with the water valve (54), and wherein the data processor / storage unit (112) is in control communication with the water valve actuator (56).

2. The batch production and continuous feeding device (2) according to claim 1 further comprises: a powder feeder (42) comprising an inlet and an outlet, wherein the outlet of the powder bin (30) is in communication with the inlet of the powder feeder (42), wherein the outlet of the powder feeder (42) is in communication with the inlet of the batch reactor (10); and A powder feeder regulator (44), wherein the powder feeder regulator (44) is in control communication with the powder feeder (42); and wherein a data processor / storage unit (112) is in control communication with the powder feeder regulator (44).

3. The batch production and continuous feeding device (2) according to claim 1 further comprises: a slurry pump (70) comprising an inlet and an outlet, wherein the inlet of the slurry pump (70) is in communication with the outlet of the product container (60); wherein the outlet of the slurry pump (70) is in communication with the inlet of the nozzle (80); and A slurry pump regulator (72); wherein the slurry pump regulator (72) is in control communication with the slurry pump (70); wherein the data processor / storage unit (112) is in control communication with the slurry pump regulator (72).

4. The batch production and continuous feeding device (2) according to claim 3, wherein: The data processor / data storage unit (112) is configured to generate a ratio of a flow rate through the slurry pump (70) to a flow rate through the air hose (86), and is configured to maintain the ratio of the slurry pump flow rate to the air hose flow rate when the air hose flow rate changes.

5. The batch production and continuous feeding device (2) according to claim 4, further comprising: The water flow sensor (52) is connected to the water supply pipe (50) in a sensing manner, wherein the data processor / storage unit (112) is connected to the water flow sensor (52) in a receiving manner.

6. The batch production and continuous feeding device (2) according to claim 4 or 5, wherein: The data processor / storage unit (112) is configured to process data received from the product container contents sensor (66) to control the powder feed valve regulator (40), the water valve actuator (56) and the batch reactor driver regulator (18).

7. The batch production and continuous feeding device (2) according to any one of claims 1 to 5, further comprising: A load measurement sensor (20) is in sensing communication with the batch reactor (10), wherein a data processor / storage unit (112) is in receiving communication with the load measurement sensor (20).

8. The batch production and continuous feeding device (2) according to any one of claims 1 to 5, further comprising: The powder bin vibration device (32) is connected to the powder bin (30), A powder silo vibration device actuator (34); wherein the powder silo vibration device actuator (34) is connected to the powder silo vibration device (32) in a controlled manner; a product container vibrating device (62) in communication with the product container (60), and A product container vibration actuator (64), wherein the product container vibration actuator (64) is in controllable communication with the product container vibration device (62).

9. The batch production and continuous feeding device (2) according to any one of claims 1 to 5, wherein: The batch reactor drive (16) is configured to supply at least 7500 watts of mechanical power to the mixing assembly (17).

10. A process for batch production and continuous feeding of refractory formulations comprising: (a) providing a batch production and continuous feeding device (2) according to any one of claims 1 to 9; (b) providing instructions to the controller (100); (c) using the data processor / storage unit (112), the powder feed valve regulator (40) and the powder feed valve (38) and data from the product container content sensor (66) to control the delivery of powder from the powder silo (30) to the batch reactor (10) to fill the batch reactor (10); (d) utilizing the data processor / storage unit (112), the batch reactor driver regulator (18), the batch reactor driver (16), and data from the product container contents sensor (66) to activate, control, and deactivate a mixing assembly (17) in the batch reactor (10) to process the powder to form a product; (e) utilizing the data processor / storage unit (112), the batch reactor door actuator (24) and the batch reactor door (22) and data from the product container contents sensor (66) to feed the product from the batch reactor (10) into the product container (60); (f) delivering the product from the product container (60) to the nozzle (80); (g) supplying air to the nozzle (80); (h) mixing the product with air in a nozzle (80); (i) spraying combined air and product; as well as (j) repeating step (c), step (d) and step (e) to produce a continuous supply of product; and wherein the batch production and continuous feeding apparatus (2) further comprises a water supply pipe (50), a water valve (54) and a water valve actuator (56); wherein the batch reactor (10) further comprises a batch reactor water inlet; wherein the water supply pipe (50) extends through the water valve (54) to reach the batch reactor water inlet; wherein the water valve actuator (56) is in controllable communication with the water valve (54); and wherein the data processor / storage unit (112) is in controllable communication with the water valve actuator (56); and wherein step (c) further comprises: (c') Utilizing the data processor / storage unit (112), the water valve actuator (56), the water valve (54), and data from the product container contents sensor (66) to control the input of water to the batch reactor (10).

11. The process for batch production and continuous loading of refractory formulations according to claim 10, wherein: If the data processor / storage unit (112) determines that the batch reactor (10) is not filled, and the product container (60) is capable of accommodating the product to be generated from the powder and water input into the batch reactor (10), and at least one of system initialization and spraying is occurring, then powder is delivered from the powder silo (30) to the batch reactor (10) and water is input into the batch reactor (10).

12. A process for batch production and continuous feeding of refractory formulations according to any one of claims 10 and 11, wherein: The batch production and continuous feeding device (2) further comprises a slurry pump (70) including an inlet and an outlet; wherein the batch production and continuous feeding device (2) further comprises a slurry pump regulator (72); wherein the inlet of the slurry pump (70) is connected to the outlet of the product container (60); wherein the outlet of the slurry pump (70) is connected to the inlet of the nozzle (80); and wherein the slurry pump regulator (72) is connected to the slurry pump (70) in a control manner; wherein the data processor / storage unit (112) is connected to the slurry pump regulator (72) in a control manner; and wherein step (d) comprises: If the data processor / storage unit (112) determines that the slurry pump (70) is activated, the batch reactor (10) is filled, and the product container (60) is capable of containing the contents of the batch reactor (10), then activating the mixing assembly (17); activating the mixing assembly (17) during system initialization if the batch reactor (10) has been filled and the product container (60) is capable of accommodating the contents of the batch reactor (10); If the data processor / storage unit (112) determines that the slurry pump (70) has been activated, the batch reactor (10) has been filled, and the product container (60) cannot accommodate the contents of the batch reactor (10), then pausing the mixing assembly (17); If the data processor / storage unit (112) determines that the batch processing is complete, deactivating the mixing assembly (17); If the data processor / storage unit (112) determines that the slurry pump (70) has been deactivated, the mixing assembly (17) is deactivated.

13. The process for batch production and continuous loading of refractory formulations according to claim 10, wherein: The batch production and continuous feeding apparatus (2) further comprises a load measurement sensor (20) in sensing communication with the batch reactor (10), wherein the data processor / storage unit (112) is in receiving communication with the load measurement sensor (20); and Data from the load measurement sensor (20) is used to control the delivery of powder from the powder silo (30) to the batch reactor (10) to fill the batch reactor (10), and to control the supply of water to the batch reactor (10).

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