Apparatus and method for batch process continuous application of fire-resistant composition

Abstract

An apparatus and process for continuously applying refractory slurry to a surface incorporates a batch reactor (10) for controlled mixing of the slurry, a product container (60) in communication with the batch reactor (10) to contain the mixed slurry, and a variable speed spray applicator or nozzle in communication with the product container and an air supply. A controller (100) controls the input to, discharge from, 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 level of slurry in the product hopper is such that the product hopper cannot accommodate additional batches of slurry, the controller suspends batch production and resumes production when the product hopper can accept the contents of the batch reactor (10).

Description

[Background technology]

[0001] Information discussed in the "Background" section is not necessarily admitted prior art.

[0002] Tundishes and ladles are intermediate containment vessels used in processing metals and metal alloys. These vessels contain a permanent refractory lining material that is resistant to high temperatures. Typically, such permanent linings are made from brick or castables and contain 50-70% Al. 2 O 3 Although these permanent lining materials are highly resistant to high temperatures, contact with molten metal and slag, as well as multiple heating and cooling cycles during molten metal processing, can degrade the permanent liners, necessitating frequent replacement of the permanent liners. Therefore, to extend the perforated life of the permanent liners, disposable liners made of dry, vibrable, trowelable, stampable, or sprayable refractory materials are formed over the permanent liners of tundishes or other molten metal processing vessels.

[0003] In the spraying process for applying the refractory composition to the permanent liner, 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 a spray nozzle, where compressed air is introduced to propel the slurry from the nozzle. The spraying process is suitable for uniform mixing because mixing occurs before the components reach the nozzle and the mixing time is not limited to the contact time of the two components in the spray nozzle.

[0004] The mixing of water and refractory powder can be accomplished in a batch process, where a predetermined amount of water and refractory powder are enclosed in a container and subjected to treatment such as stirring. The batch process offers ease of control of processing conditions such as the intensity of stirring, 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 accomplished in a continuous process, where the water and refractory powder are introduced into the container inlet and combined and processed as they move through the container to the container outlet. However, in a continuous process, it is difficult to control the process conditions. Although the spraying process is most often a continuous process, the application rate of the slurry can vary and can be intermittent for various reasons. The need for slurry in the application process is not constant. Nevertheless, the spraying process relies on a constant supply of slurry.

[0005] It has been found that properties such as density and porosity of a particular sprayed refractory composition are dependent 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 generate successive batches of slurry to feed the spray nozzle requires monitoring of the rate of slurry consumption and the amount of slurry available so that mixing of the slurry can be controlled when batch mixing is used.

[0006] WO199711802 to Daussan discloses a method and apparatus for producing and spraying an aqueous slurry. The aqueous slurry is mechanically agitated to foam and / or swell the surfactant, adjusting the agitation power and / or speed and / or time to control the foaming and / or swelling rate of the surfactant and thus vary the porosity of the sprayed coating. However, no method or apparatus is disclosed in which the start of a batch process feeding a continuous coating process is controlled by data generated by a sensor on a storage vessel feeding directly to the coater so that a constant supply of slurry can be produced.

[0007] US 4,298,288 to Weisbrod discloses a mobile concrete pouring method and apparatus in which multiple components are fed in a controlled manner to a mixer to produce a slurry. The slurry is transferred from the mixer to a nozzle and from there to the surface to be coated. However, the Weisbrod method is not a batch processing method and the Weisbrod apparatus is not configured for batch processing. Thus, there is no disclosure of a method or apparatus in which the initiation of a batch process feeding a continuous coating process is controlled by data generated by a sensor on a storage vessel that feeds directly to an applicator so that a constant supply of slurry can be produced.

[0008] EP0286513A1 ((DAUSSAN and CO [FR]) 12 October 1988 (1988-10-12)) is directed to a method and apparatus for applying a thermal insulating fireproof coating comprising at least two layers of equal or different thickness, of different composition and equal or different water content, to a surface such as the inside of a metallurgical vessel. The apparatus incorporates a powder bin, a valve for allowing or blocking flow from the powder bin, a mixing element for receiving material as well as water from the powder bin, a product container for receiving material from the mixing element, a sensor for sensing the volume or level of the mixed material in the product container, a controller for regulating at least the amount of water in the mixture, and a nozzle for applying the mixture. The apparatus is capable of producing a formulation having a preselected density by varying the amount of ingredients flowing into the batch process, but is unable to control the mixing energy introduced into the batch process over a defined period of time to produce a formulation having a preselected density.

[0009] DE 4217373 A1 ((KLAUS OBERMANN GMBH [DE]) 16 December 1993 (1993-12-16)) discloses an apparatus for preparing mixtures or suspensions (e.g. water-cement mixtures, water-bentonite suspensions, etc.) containing one liquid component, the apparatus having a mixer to which doses of liquid and solid (powder, granular, paste, or slurry) components are supplied from separate sources, followed by a pump for transporting the final mixture in a supply container or in a pipeline leading to a consumer. The mixer is a continuous mixer, to which the liquid and solid components are continuously supplied in amounts corresponding to the final mixture discharged via the pump. The apparatus is not configured to incorporate batch processes, in which, for example, a controlled amount of mixing energy may be introduced into the batch over a defined period of time.

[0010] It would therefore be advantageous to develop equipment and processes that offer the advantages of both batch and continuous processes combining the components of the fire resistant composition for sprayable application, allowing for continuous production of products capable of achieving a range of density values ​​with a single formulation. [Prior art documents] [Patent documents]

[0011] [Patent Document 1] WO1997 / 11802 [Patent Document 2] US4298288 [Patent Document 3] EP0286513A1 [Patent Document 4] DE4217373A1 Summary of the Invention

[0012] The invention described herein is directed to an apparatus and process for the batch production of refractory slurries and for their continuous spray application.

[0013] An exemplary apparatus of the present invention includes a batch reactor configured to mix components of a formulation to produce a refractory slurry. The batch reactor is in communication with a plurality of inlets. Flow or passage through each reactor inlet is regulated by actuators controlling, for example, pumps, feeders, or valves located at the respective feed inlets. The inlets provide communication between respective feed lines or storage vessels through respective actuators to the batch reactor. The batch reactor includes a reactor outlet that, when positioned and open, delivers the contents of the reactor vessel into a product vessel. The product vessel includes a product vessel outlet through which the contents of the product vessel may pass.

[0014] The product container outlet is in fluid communication with a coater pump which is in fluid communication with the coater via an coater product inlet. An air source inlet, the flow of which is regulated by an air source valve, also communicates with the coater. Within the coater, the air source inlet and the product inlet join to form an outlet through which the coater nozzle passes.

[0015] The controller accepts information input from the human interface and from the sensors. The product quantity sensor provides the controller with a measurement of the amount of product in the product container. The flow rate sensor provides a measurement of the flow rate through the air source inlet and the product inlet. The controller controls an actuator that regulates the flow or passage through the reactor fill inlet. The controller controls an actuator that regulates the start, end, and rate or intensity of a process such as mixing in the batch reactor. The controller controls an actuator fixed to the batch reactor outlet that regulates the opening and closing of the batch reactor outlet. The controller controls a coater pump actuator in communication with the coater pump that starts, stops, or regulates the rate of product transport through the actuator pump. The air source inlet actuator starts, stops, or regulates the flow of air through the air source inlet.

[0016] The process of applying a fire resistant composition according to the present invention is carried out in the following manner: A fill port is positioned to receive the formulation components into the batch reactor. Information is input to the controller, including the batch formulation, batch mixing time, and rate. The controller controls the actuator to flow the formulation components into the batch reactor. The controller controls the actuator to start the batch production, to regulate the batch production, and to stop the batch production when the process is complete. Upon completion of the batch production, the controller receives input from a product container volume sensor to determine whether the contents of the batch reactor can be accommodated in the product container. If the contents of the batch reactor can be accommodated in the product container, the controller signals the actuator to open the batch reactor outlet and the processed batch is transferred to the product container and can be conveyed to the nozzle by the slurry pump. At this point spraying can commence to begin processing a new batch.

[0017] A continuous supply of batch produced formulation can be maintained as follows.

[0018] The controller maintains or retrieves information regarding the on / off status of the slurry pump, the presence or absence of a batch in the batch reactor, the size of the batch in the batch reactor, the on / off status of the batch reactor drive, the remaining mixing time for the batch in the batch reactor, the amount of slurry in the product vessel, and whether the batch process continuous application device is initialized (i.e., the product vessel is partially or completely filled with slurry before spraying begins).

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

[0020] When the slurry pump is pumping, the amount of slurry in the product vessel is periodically monitored to derive the product vessel capacity. The product vessel capacity is the amount of slurry that can be accepted from the batch reactor, which is the result of subtracting the amount of slurry in the product vessel from the amount of slurry that can be accepted from the batch reactor when the product vessel is empty. The product vessel capacity is compared to the amount of slurry in the batch reactor. The controller takes action on the comparison of the capacity in the product vessel (AA) to the amount of slurry in the batch reactor (BR), the presence / absence of batch in the batch reactor (Y / N), the on / off operation status of the batch reactor drive (BRD), and the remaining mix time (RMT) of the batch in the batch reactor.

[0021] If AA>BR, BR:N, and BRD:OFF, flow the blend ingredients into the batch reactor, turn on BRD, and begin batch processing. The situation where AA>BR, BR:N, and BRD:ON should not occur in normal operation.

[0022] If AA>BR, BR:Y, BRD:Off, and RMT>0, turn on the BRD and complete the batch process. Upon completion of the batch process, turn off the BRD and discharge the processed batch from the batch reactor.

[0023] If AA>BR, BR:Y, BRD:On, and RMT>0, then the BRD will remain on until batch processing is complete, at which point the BRD will be turned off and the processed batch will be discharged from the batch reactor.

[0024] If AA>BR, BR:Y, BRD:On, and RMT=0, then turn off BRD and discharge the processed batch from the batch reactor.

[0025] If AA>BR, BR:Y, BRD:off, and RMT=0, the processed batch is discharged from the batch reactor.

[0026] When AA < BR, BR: N, and BRD: off, perform actions until AA > BR. The situation where AA < BR, BR: N, and BRD: on does not occur during normal operation.

[0027] When AA < BR, BR: Y, BRD: on, and RMT > 0, turn off BRD until AA > BR.

[0028] When AA < BR, BR: Y, BRD: off, and RMT > 0, keep BRD off until AA > BR.

[0029] When AA < BR, BR: Y, BRD: on, and RMT = 0, turn off BRD and hold the processed batch in the batch reactor.

[0030] When AA < BR, BR: Y, BRD: off, and RMT = 0, keep BRD off and hold the processed batch in the batch reactor.

Brief Description of the Drawings

[0031] Various features and characteristics of the present invention described herein can be more fully understood by referring to the accompanying drawings.

[0032] [Figure 1] It is a schematic diagram of a refractory slurry production and coating apparatus. [Diagram 2] It is a schematic diagram of data collection and control elements of a refractory slurry production and coating apparatus.

[0033] The reader will understand the above features and characteristics, as well as other features and characteristics, by considering the following detailed description of the present invention.

Modes for Carrying Out the Invention

[0034] The refractory compositions described herein produce a working lining or other refractory structure that provides antioxidant barrier properties during use in a metallurgical vessel. As used herein, including the claims, the term "working lining" refers to the innermost refractory layer that contacts the molten metal contained in the metallurgical vessel. As used herein, including the claims, the term "metal" refers to metals and metal alloys. As used herein, the phrase "in receiving communication with" is used to describe a device or element of a device that accepts data, such as data in electronic form emitted from another device or element of a device. As used herein, the phrase "in sensing communication with" is used to describe a device or element of a device that measures, analyzes, or derives information from another device, element of a device, the contents of a device, or a material sample. As used herein, the phrase "in control communication with" is used to describe a device or element of a device that transmits commands to another device or element of a device. As used herein, the phrase "in communication with" is used to describe contact that may be indirect, via an intermediate element, or direct, where there is no intermediate element.

[0035] FIG. 1 is a schematic diagram of a batch process continuous coating apparatus 2 configuration including a batch reactor 10. The batch reactor 10 includes a powder feed port 12 and a feed water inlet 14. The batch reactor 10 includes a batch reactor drive 16 that is attached to, in mechanical communication with, and capable of imparting motion to a mixer 17, which may include blending, combining, shaking, or stirring 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, which is in control communication with the batch reactor drive 16. The batch reactor drive regulator 18 may start, stop, or vary the speed of the mixer 17 within the batch reactor 10. A load measurement sensor 20 provides a weight measurement of the contents of the batch reactor 10. The load measurement sensor 20 is in sensing communication with the batch reactor 10.

[0036] The contents of the batch reactor are removed through a batch reactor door 22 that is controlled by a batch reactor door actuator 24, which opens and closes the batch reactor door 22. The batch reactor door 22 constitutes the exhaust of the batch reactor 10. The batch reactor door actuator 24 is in control communication with the door 22. To operate the batch reactor door 22, a five-port two-way valve in communication with the batch reactor door actuator 24 may be used.

[0037] The powder bin 30 includes a powder bin vibration device 32 that is regulated by a powder bin vibration actuator 34. The powder bin vibration device 32 may be attached to or in communication with the powder bin 30. The powder bin vibration device actuator 34 is in control communication with the powder bin vibration device 32. Powder is delivered from the powder bin 30 through a powder feed valve 38 that is regulated by a powder feed valve regulator 40 to an inlet of a powder feeder 42 that has an inlet and an outlet, includes a motor, and includes a material transfer device such as a screw or an auger. The powder feeder 42 is controlled by a powder feeder regulator 44. The powder feeder regulator 44 allows for the transfer of a selected amount of powder to the batch reactor 10. Measurements from the load measurement sensor 20 are processed and provided to the powder feeder regulator 44 to load a predetermined amount of powder into the batch reactor 10. The powder exiting the powder feeder 42 is delivered to the powder feed port 12 of the batch reactor 10. A five-port two-way valve may be used as powder feed valve 38. Powder feed valve 38 and powder feed valve regulator 40 may be integrated. Powder bin 30 has an outlet, powder feed valve 38 may be located at or near the powder bin outlet, and powder feed valve regulator 40 is in controlling communication with powder feed valve 38. The outlet of powder bin 30 communicates with the inlet of the batch reactor.

[0038] Water conduit line 50 passes or passes through a water flow sensor 52 and enters the feedwater inlet 14 of the batch reactor 10 through a water valve 54 controlled by a water valve actuator 56. The water valve actuator 56 enables the transfer of 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 conduit 50. The water flow sensor 52 may include a water rotor and a Hall effect sensor.

[0039] After mixing, the contents of the batch reactor 10 are delivered to a product container 60 through the batch reactor door 22. The product container 60 has a feed inlet and a discharge inlet, the feed inlet of the product container 60 configured to receive the contents of the batch reactor 10 through the door 22. In the configuration shown, the door 22 is located above the feed inlet to the product container 60, and the contents of the batch reactor 10 passing through the door 22 drop into the product container 60. The product container 60 includes a product container vibration device 62 that is regulated by a product container vibration actuator 64. The product container vibration device 62 may be attached to the product container 60 or may 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 includes a product container measurement sensor 66 for measuring the amount of slurry 68 in the product container 60. The product container contents sensor 66 may be in sensing communication with the contents 68 of the product container 60. The product container 60 has a frustum shaped lower portion with its smallest radius located adjacent the outlet of the product container 60 .

[0040] The contents of the product vessel 60 are delivered to a supply inlet of a slurry pump 70. The slurry pump 70 has a supply inlet and an outlet. The supply inlet of the slurry pump 70 is in direct or indirect communication with the outlet of the product vessel 60. The slurry pump 70 includes a motor and a material transfer structure, such as a screw. The slurry pump 70 is regulated by a slurry pump regulator 72. The slurry pump regulator 72 is in control communication with the slurry pump 70.

[0041] The discharge of the slurry pump 70 is propelled through a slurry hose 76 to a nozzle 80. The discharge of the slurry pump 70 communicates with the supply inlet of the nozzle 80.

[0042] Air enters nozzle 80 through air hose 86, through air supply valve 88 which is controlled by air supply valve actuator 90, and across or through air flow sensor 92. Air flow sensor 92 can be an analog or digital device.

[0043] At the nozzle 80, air is injected into the slurry stream just prior to the outlet tip. The slurry is propelled from the outlet tip of the nozzle 80. The nozzle 80 has a feed port and an outlet. The nozzle feed port receives the discharge of the outlet of the product container 60 and the nozzle feed port receives the discharge of the air hose 86. The nozzle feed port may be divided into separate chambers including a chamber for receiving the discharge of the outlet of the product container 60 and a chamber for receiving the discharge of the air hose 86, in this configuration the product container chamber and the air chamber are in contact with the nozzle 80 and in communication with the nozzle outlet. 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.

[0044] Control of the batch process continuous coating apparatus 2 is accomplished by a controller 100, which includes a controller human / machine interface (HMI) display 102, a control panel 104, a command transmission port 106, a data collection port 108, and a processor 112. The human / machine interface display 102 is a device that allows for interaction between humans and machines and can accept and implement operator control commands and present information to the operator regarding the status of the process. The control panel 104 is a surface that can include manual controls such as switches, buttons, knobs, or keypads for operating the apparatus and can include display components such as gauges and video screens for providing apparatus status information.

[0045] Figure 2 is a schematic diagram of the controller 100 and the controller connections 101 of the device according to Figure 1. The controller comprises a human / machine interface display 102 and a control panel 104 for viewing process data and inputting commands, respectively. The human / machine interface display 102 and the control panel 104 can be separate or integrated devices.

[0046] The controller 100 includes a command transmission port 106. Through the command transmission port 106 the controller is linked to the batch reactor drive regulator 18, the batch reactor door actuator 24, the powder bin vibration actuator 34, the powder feed valve regulator 40, the powder feeder regulator 44, the water valve actuator 56, the product bin vibration actuator 64, the slurry pump regulator 72 and the air feed valve actuator 90.

[0047] The controller 100 includes a data collection port 108. Through the data collection port 108, the controller is linked to the load measurement sensor 20, the water flow sensor 52, the product container measurement sensor 66, and the air flow sensor 92.

[0048] The controller 100 includes a data processor / storage unit 112 that accepts and is in receiving communication with 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. The data processor / storage unit 112 performs calculations and logical operations on data provided from the interface 102, the control panel 104, the sensors 20, 52, 66, and 92, and internally stored data. Commands based on the results of the calculations and logical operations are issued through a command transmission port to the regulators and actuators 18, 24, 34, 40, 44, 56, 64, 72, and 90. The data processor / storage unit 112 is in control communication with the regulators and actuators 18, 24, 34, 40, 44, 56, 64, 72, and 90.

[0049] The connections 101 between the controller and the various actuators and sensors can be made by wires, fiber optic cables, or wireless cooperation. The devices can be cooperated by Ethernet / IP.

[0050] Specialized elements may be used in the devices described herein.

[0051] The batch reactor 10 may take the form of a closed vessel with an internal mixer configured to mix the contents of the batch reactor 10. The batch reactor 10 may include a batch reactor drive 16, such as a 7500 watt gear motor connected to a variable frequency drive, and a mixer 17, which may include a mixing blade, such as a batch reactor tilted mud whip type mixing blade, connected to a rotating shaft driven by the batch reactor drive 16. The batch reactor 10 may take the form of a drum paddle mixer. The batch reactor 10, formed from a 0.25 cubic meter slurry containing drum, contains a 90 kg batch of refractory slurry. An air piston may be used as the batch reactor door actuator 24. The batch reactor door 22 is typically located at the bottom of the batch reactor 10. A product container 60 may be located below the batch reactor door 22 so that the completed batch may be discharged 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 dictated by the operator setpoints. By introducing low or high shear and intense mixing energy into the batch process for a defined period of time, the physical properties of the slurry can be altered to the desired outcome. The motor power can be 7500 watts or more, and it has been found that motor powers of 7500 watts or more are required to reduce the density of the refractory batch. The batch reactor drive 16 can be configured to provide at least 7500 watts of mechanical power to the mixer 17.

[0052] The load measurement 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.

[0053] To eliminate bridging, material sticking, and uneven flow, a powder bin vibrator 32 regulated by a powder bin vibration actuator 34 may be used with the powder bin 30. The powder bin vibrator 32 may be electrically or pneumatically driven. Typically, the powder bin vibrator 32 is in physical contact or communication with the powder bin 30. An 1800 kg storage bin may be suitable for use as the powder bin 30 in the batch process continuous coating apparatus 2.

[0054] The powder feeder 42 may include a motor, such as a 750 watt electric gear motor connected to a variable frequency drive. Powder feeding may be accomplished by a conveyor, such as a 10 cm auger type screw.

[0055] The water valve actuator 56 for the water valve 54 may be a two-way fluid solenoid.

[0056] The slurry level measurement sensor 66 may be a laser distance sensor. It may be located in or on the product container 60. It may be oriented towards the outlet port of the product container 60.

[0057] 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 paddle feeder, a rotor stator assembly, and an oscillating pneumatic motor. A slurry containment hopper, which may have a volume of 0.17 cubic meters, may be positioned to receive slurry from the product container 60. When this configuration is operational and slurry is present, the pump delivers the slurry from the containment hopper through the use of a paddle feeder that rotates at different speeds to force the slurry into the rotor stator assembly where it is evenly pushed through the pump discharge. The oscillating pneumatic motor evens out the slurry in the slurry hopper so that the container measurement sensor 66 obtains an accurate measurement of the slurry volume 68 in the product container 60.

[0058] In a typical configuration, the spray nozzle 80 includes a 30 cm by 2.5 cm diameter hydraulic hose section connected to a cast aluminum nozzle head with integral atomizing air and tubes and a 12 mm atomizing rubber nozzle cap. As the slurry is pumped into the nozzle, low pressure air is injected into the slurry stream just prior to the discharge port (a 12 mm hole concentric with the atomizing air tube). This action creates a conical pattern of slurry that is then applied to the surface.

[0059] The air supply valve actuator 90 for the air supply valve 88 may be a two-way fluid solenoid.

[0060] Machine control may be accomplished by using an Allen Bradley Micrologixs 1400 PLC controller as the controller 100 and a C-More Human Machine Interface display as the human / machine interface display 102. A human / machine interface display is a screen that allows a user to interact with a device, such as a device that runs or controls an industrial process.

[0061] Formulations that can be used with the disclosed apparatus include calcium aluminate cement and alumina formulations containing dispersants. The batch process continuous application apparatus allows for the production of refractory slurries in a range of densities from a single component mixture, but also allows for the production of successive batches of refractory slurries with different moisture contents.

[0062] The batch process continuous application apparatus 2 may be configured to prevent the production of excess slurry. If the product container 60 cannot accommodate the batch reactor 10, the product container measurement sensor 66 identifies the excess slurry in the product container 60 (e.g., by providing information to the data processor / storage unit 112 regarding the determination 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 sufficient slurry is discharged from the product container 60 so that additional batch can be discharged from the batch reactor 10 and contained entirely within the product container 60. The "hold" state may include stopping the mixing process and / or stopping the transfer of slurry from the batch reactor 10 to the product container 60. This may be accomplished with a configuration of the apparatus 2 in which the data processor / storage unit 112 is configured to process data received from the product container contents sensor 66 to control the batch reactor drive regulator 18 and the batch reactor door actuator 24.

[0063] The batch process continuous application apparatus 2 also includes a function that, if the product container 60 is unable to accommodate the batch reactor 10, the product container measurement sensor 66 identifies excess slurry in the product container 60 (e.g., by providing information to the data processor / storage unit 112 regarding the determination that the product container 60 is unable to accommodate the contents of the batch reactor 10), and the data processor / storage unit 112 stops the transfer of powder, water, and other formulation ingredients to the batch reactor 10 until sufficient slurry has been discharged from the product container 60 so that the additional batch can be discharged from the batch reactor 10 and fully contained within the product container 60. This may 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 contents 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 may also process data received from the product container contents sensor 66 to control the batch reactor door actuator 24.

[0064] The batch process continuous coating apparatus 2 may also be configured to prevent a coating process shutdown due to a 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 at a predetermined minimum amount or at a 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 in the product container 60 is at a low level, the data processor / storage unit 112 performs a calculation based on the cumulative slurry usage rate (S / T), data obtained from the amount of slurry 68 (S) 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 so that it is less than (S / (RMT)).

[0065] In terms of construction, the outlet of the powder bin 30 communicates with the inlet of the powder feed valve 38. The outlet of the powder feed valve 38 communicates with the inlet of the powder feeder 42. The outlet of the powder feeder 42 communicates with the batch reactor powder feed port 12 of the batch reactor 10. A water line 50 extends from a water source through a water valve 54 to the batch reactor feed water inlet 14. The outlet of the batch reactor 10 communicates with an inlet of a product container 60. The outlet of the product container 60 communicates with the input of a slurry pump 70. The outlet of the slurry pump 70 communicates with an inlet or inlet of a nozzle 80. An air supply line extends from a source of pressurized air through an air supply valve 88 and an air hose 86 to the inlet or inlet of the nozzle 80. Air from air hose 86 and the product or contents of slurry hose 76 are combined within and sprayed through nozzle 80 .

[0066] The method of producing and continuously applying a fireproofing composition to a surface by the batch process continuous application apparatus 2 is carried out as follows: Dry ingredients of the formulation are introduced into the powder bin 30. The powder bin vibrator 32 may be actuated by a powder bin vibrator actuator which may be controlled by the data processor / storage unit 112 of the controller 100 via a command transmission port 106. An operator inputs batch production settings and instructions, such as batch size, moisture content, dry ingredient content, mixing time, and mixing speed, as well as commands to start batch production, into the controller 100 via the controller human / machine interface display 102, control panel 104, or other input device. The controller 100, through the command transmission port 106, transmits to the powder feed valve regulator 40 and the powder feed valve 38, and / or to the powder feeder regulator 40. 4to transfer the dry ingredients from the powder bin 30 to the inlet of the powder feeder 42. The dry ingredients are transferred 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 transferred from the powder bin 30 to the batch reactor 10 can be determined by the load measuring sensor 20 by the difference before and after the transfer. Thus, data from the load measuring sensor 20 can be used to control the transfer of powder from the powder bin 30 to the batch reactor 10.

[0067] The controller 100 sends commands to the water valve actuator 56 and the water valve 54 through the command sending port 106 to introduce water from the water line 50 into the batch reactor 10. The amount of water transferred to the batch reactor 10 can be obtained by the water flow sensor 52 or can be determined by the load measuring sensor 20 by the difference before and after the transfer. Thus, data from the load measuring 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 line 50 or into the batch reactor 10 from a separate vessel equipped with a valve and valve actuator. The controller 100 derives the amount (or mass or density) of material in the batch reactor 109 from the data provided by the sensor 52 and / or the sensor 20.

[0068] The process of placing batch ingredients into the batch reactor 10 is referred to as "filling". Once all the batch ingredients have entered the batch reactor 10 in the selected amounts, the controller 100 sends a command through a command transmission port to the batch reactor driver regulator 18 to operate the batch reactor driver 16 to begin the mixing process in the batch reactor 10. The controller 100 regulates the start, completion, pause, length of time, and intensity of mixing. The controller 100 also calculates and maintains a value of the remaining mixing time. The mixing intensity is related to the rotational speed of the mixing arrangement and the speed of the mixer 17 arrangement, such as the mixing blades or paddles, in the batch reactor 10. The batch reactor 10 may include any known type of agitator. The batch size, mixing time, and mixing intensity of a certain combination of ingredients may be selected based on a calibration table that relates the combination of batch size, mixing time, and mixing intensity of the particular combination of ingredients to produce a slurry having a specified density.

[0069] 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 through the data collection port 108 so that the amount of product in the product container 60 can be determined by the data processor / storage unit 112. If the product container 60 cannot accommodate the batch being mixed, the controller 100 sends a command to the batch reactor drive actuator 18 to pause batch mixing until the product container 60 can accommodate the batch. If a batch is not mixed and the product container 60 cannot accommodate the next batch to be mixed, the combination of ingredients and the start of batch mixing is postponed until the product container 60 can accommodate the batch. Typically, the process container 60 accommodates at least two batches produced by the batch reactor 10, so the batch mixing process does not need to be stopped during the production of the first batch.

[0070] When batch mixing is complete and the contents of the batch mixer 10 can be accommodated by the product container 60, the controller 100 sends 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 transferred to the product container 60. The product container 60 may include a product container vibrator 62 in communication with a product container vibration actuator 64. The product container vibrator 62 may be electrically or pneumatically powdered. The product container vibrator 62 ensures that the slurry remains in contact with and exits through the outlet port of the product container 60. The presence of product in the product container 60, which may be sensed by a product container contents sensor 66, may be received by the controller 100 and used by the data processor / storage unit 112 to communicate a command to the product container vibrator actuator 64 to initiate operation of the product container vibrator 62.

[0071] The portion of the process that occurs before spraying begins may be referred to as system initialization. Spraying of slurry may begin when product is present in the product container 60. The controller 101 sends commands to the slurry pump regulator 72 to control the rate at which the slurry pump 70 pumps to provide product or slurry to the nozzle 80, and also sends 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. Slurry flows from the slurry pump 70 through the slurry hose 76 to the nozzle 80, and air flows through the nozzle 80 to the air hose 86. The air flow sensor 92 sends flow information to the controller 100, which sends commands to the slurry pump regulator 72 and the air supply valve actuator 90 to balance the flow rates through the slurry pump 70 and the air hose 86 so that the slurry is sprayed from the nozzle 80 at the intended pressure. The operator may 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, which in certain configurations of the apparatus maintains the pumping rate of the slurry pump 70 at a set ratio to the rate of air flow through the air supply valve 88. The data processor / storage unit 112 may 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 to maintain the ratio of the slurry pump volume to the air hose flow rate as the air hose flow rate is changed. The operator may stop 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, which in certain configurations of the apparatus shuts off the slurry pump 70 when the air flow through the air supply valve 88 is shut off.In certain configurations of the batch process continuous coating apparatus 2, the shutoff of the slurry pump 70 and / or the air supply following system initialization will inhibit the initiation of the batch process in the batch mixer 10. Data provided by the product container contents sensor 66 may be received by the controller 100 and used by the data processor / storage unit 112 to inhibit the initiation of batch processing in the batch mixer 10 or the introduction of formulation components to the batch mixer 10 if the new batch cannot be accommodated by the product container 60.

[0072] A method for using the apparatus described herein to batch produce and continuously apply a fire resistant composition to a surface comprises the steps of: (a) providing a batch process continuous coating apparatus 2 according to claim 1; (b) providing instructions to the controller 100; and (c) utilizing data from the data processor / storage unit 112, the powder feed valve regulator 40, and the powder feed valve 38, and the product container contents sensor 66, to control the transfer of powder from the powder bin 30 to the batch reactor 10 to fill the batch reactor 10; (d) utilizing data from the data processor / storage unit 112, the batch reactor drive controller 18, the batch reactor drive 16, and the product container contents sensor 66 to activate, control, and stop the mixer 17 in the batch reactor 10 to process the powder and form the product; (e) utilizing data from 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, delivering product from the batch reactor 10 to the product container 60; (f) transferring product from the product container 60 to the nozzle 80; (g) providing air to the nozzle 80; (h) combining the product with air in a nozzle 80; (h) spraying the combined air and product; (i) repeating steps (c), (d), and (e) to produce a continuous supply of product.

[0073] Step (c) may further include (c') controlling the input of water to the batch reactor 10 utilizing data from the data processor / storage unit 112, the water valve actuator 56, the water valve 54, and the product container contents sensor 66.

[0074] Step (c) may include a restriction to allow transfer of powder from powder bin 30 to batch reactor 10 and input of water to batch reactor 10 when data processor / storage unit 112 determines that batch reactor 10 is not full, product container 60 can accommodate product produced from powder and water input to batch reactor 10, and at least one of system initialization (product is produced at the start of operation before spraying can begin) and spraying is occurring.

[0075] Step (d) is operating the mixer 17 when the data processor / storage unit 122 determines that the slurry pump 70 is operating, the batch reactor 10 is filled, and the product vessel 60 is capable of accommodating the contents of the batch reactor 10; activating mixer 17 during system initialization when batch reactor 10 is filled and product container 60 is capable of accommodating the contents of batch reactor 10; pausing the mixer 17 when the data processor / storage unit 122 determines that the slurry pump 70 is running, the batch reactor 10 is filling, and the product vessel 60 cannot accommodate the contents of the batch reactor 10; stopping the mixer 17 when the data processor / storage unit 122 determines that the batch processing is complete; Stopping the mixer 17 if the data processing / storage unit 122 determines that the slurry pump 70 has been stopped.

[0076] Data from the load measurement sensor 20 can be used to control the transfer of powder from the powder bin 30 to the batch reactor 10 for filling the batch reactor 10, and to control the supply of water to the batch reactor 10. EXAMPLES

[0077] The batch process continuous application apparatus 2 is capable of producing refractory slurries having a range of densities from a single component mixture. Various densities are produced by mixing the components at specific values ​​of a range of mixing times and speeds. Calibration tables showing the slurry densities produced for various combinations of mixing times, mixing speeds, and spray pressures allow the apparatus to be programmed and instructions entered to produce formulations having the desired densities.

[0078] Example 1: The following table shows the results of experiments performed to correlate mixer speed and agitation time in a batch reactor with density as a function of density reduction. The baseline density of this formulation using a conventional continuous mixer was about 120 lb / ft 3 (1920kg / m 3 ). The dry ingredient mixture contained 93% refractory, 0.25% anionic surfactant, and binder material. The dry ingredient mixture was mixed with water to produce a slurry containing 20 weight percent water. 200 lb (90 kg) batches of mixed dry ingredients were batch mixed for 7 minutes. Water was then added and the batch mixed for the time period and at the speed shown in Table I. Density was obtained for the slurry when removed from the batch mixer or after spraying, as shown in the table. [Table 1]

[0079] element: 2. Batch process continuous coating equipment 10. Batch Reactor 12. Batch reactor powder feeding port 14. Batch reactor feed water inlet 16.Batch reactor drive unit 17. Mixer 18. Batch reactor drive controller 20. Load measurement sensor 22.Batch reactor door 24.Batch reactor door actuator 30. Powder bottle 32. Powder bottle vibrator 34. Powder Bin Vibrator Actuator 38. Powder supply valve 40.Powder feed valve regulator 42.Powder feeding device 44.Powder feeding device regulator 50. Water pipe 52.Water flow sensor 54. Water valve 56.Water valve actuator 60. Product container 62.Product container vibration device 64. Product container vibration device actuator 66. Product container content sensor 68. Product container contents 70. Slurry pump 72. Slurry pump regulator 76. Slurry hose 80. Nozzle 86. Air Hose 88.Air supply valve 90.Air supply valve actuator 92.Air flow sensor 100. Controller 101. Controller connection 102.Controller Human / Machine Interface Display 104. Control Panel 106. Command sending port 108. Data Collection Port 112. Data Processor / Storage Unit

[0080] Aspects of the invention Various inventive aspects include, but are not limited to, the following numbered items:

[0081] 1. A batch process continuous coating device 2, a powder bottle 30 having an outlet; a powder feed valve 38 located at the powder bin outlet; a powder feed valve regulator 40 in controlling communication with the powder feed valve 38; A batch reactor 10 comprising a feed inlet 12, a door 22, a batch reactor drive 16, a mixer 17, a batch reactor drive regulator 18, the door 22, and a batch reactor door actuator 24, wherein an outlet of a powder bin 30 communicates with the feed inlet 12 of the batch reactor, the batch reactor drive regulator 18 is in control communication with the batch reactor drive 16, the batch reactor drive 16 is in mechanical communication with the mixer 17, and the batch reactor door actuator 24 is in control communication with the door 22; a product container 60 having an inlet and an outlet, the inlet of the product container 60 being configured to receive the contents of the batch reactor 10 passing through the door 22; a product container contents sensor 66 adapted to sense an amount of contents 68 of the product container 60; a controller 100 including a data processor / storage unit 112, the data processor / storage unit 112 in receiving communication with a product container contents sensor 66, the data processor / storage unit 112 in control communication with a powder feed valve regulator 40, the data processor / storage unit 112 in control communication with a batch reactor drive regulator 18, and the data processor / storage unit 112 in control communication with a batch reactor door actuator 24; a nozzle 80 having a supply inlet and an outlet, the nozzle supply inlet receiving the discharge of a product container 60 outlet, the nozzle supply inlet receiving the discharge of an air hose 86, the flow of air in the air hose 86 being regulated by an air supply valve 88 and controlled by an air supply valve actuator 90;

[0082] 2. A powder feeder 42 having an inlet and an outlet, the outlet of the powder bin 30 communicating with the inlet of the powder feeder 42, and the outlet of the powder feeder 42 communicating with the inlet 14 of the batch reactor 10; A powder feeder regulator 44, regulator 44 in control communication with the powder feeder 42, and a data processor / storage unit 112 in control communication with the powder feeder regulator 44.

[0083] 3. A slurry pump 70 having a supply inlet and a discharge outlet, the supply inlet of the slurry pump 70 communicating with the discharge outlet of the product container 60, and the discharge outlet of the slurry pump 70 communicating with the supply inlet of the nozzle 80; The batch process continuous coating apparatus 2 according to item 1 or 2, further comprising a slurry pump regulator 72, the slurry pump regulator 72 being in control communication with the slurry pump 70, and a data processor / storage unit 112 being in control communication with the slurry pump regulator 72.

[0084] 4. Water valve 54; a water pipe 50, the water pipe 50 extending through a water valve 54 to the batch reactor water supply inlet 14 of the batch reactor 10; The batch process continuous coating apparatus 2 described in any one of items 1 to 3 further comprises a water valve actuator 56, the water valve actuator 56 being in control coordination with the water valve 54, and the data processor / storage unit 112 being in control coordination with the water valve actuator 56.

[0085] 5. A batch process continuous coating apparatus 2 described in any of items 1 to 4, further comprising a water flow sensor 52 in sensing communication with the water pipe 50, and a data processor / storage unit 112 in receiving communication with the water flow sensor 52.

[0086] 6. A batch process continuous coating apparatus 2 as described in any of items 1 to 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 feeding valve regulator 40, the water valve actuator 56, and the batch reactor drive regulator 18.

[0087] 7. A batch process continuous coating apparatus 2 described in any of items 1 to 6, further comprising a load measuring sensor 20 in sensing communication with the batch reactor 10, and a data processor / storage unit 112 in receiving communication with the load measuring sensor 20.

[0088] 8. A powder bottle vibrator 32 associated with the powder bottle 30; a powder bin vibrator actuator 34 in control communication with the powder bin vibrator 32; a product container vibration device 62 associated with the product container 60; The batch process continuous coating apparatus 2 according to any one of items 1 to 7, further comprising a product container vibration actuator 64 that is in control cooperation with the product container vibration device 62.

[0089] 9. A batch process continuous coating apparatus 2 as described in any of items 1 to 8, wherein the data processor / storage unit 112 is configured to generate a ratio of the flow rate through the slurry pump 70 and the flow rate through the air hose 86, and to maintain the ratio of the slurry pump flow rate and the air hose flow rate when the air hose flow rate changes.

[0090] 10. A batch process continuous coating apparatus 2 according to any one of items 1 to 9, wherein the batch reactor drive device 16 is configured to supply at least 7500 watts of mechanical power to the mixer 17.

[0091] 11. A method for batch process continuous application of a fire resistant composition, comprising: (a) providing a batch process continuous coating apparatus 2 according to item 1; (b) providing instructions to the controller 100; and (c) utilizing data from the data processor / storage unit 112, the powder feed valve regulator 40, and the powder feed valve 38, and the product container contents sensor 66, to control the transfer of powder from the powder bin 30 to the batch reactor 10 to fill the batch reactor 10; (d) utilizing data from the data processor / storage unit 112, the batch reactor drive controller 18, the batch reactor drive 16, and the product container contents sensor 66 to activate, control, and stop the mixer 17 in the batch reactor 10 to process the powder and form the product; (e) utilizing data from 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, delivering product from the batch reactor 10 to the product container 60; (f) transferring product from the product container 60 to the nozzle 80; (g) providing air to the nozzle 80; (h) combining the product with air in a nozzle 80; (i) spraying the combined air and product; (j) repeating steps (c), (d), and (e) to produce a continuous supply of product.

[0092] 12. The batch process continuous coating apparatus 2 further comprises a water pipe 50, a water valve 54, and a water valve actuator 56, the batch reactor 10 further comprises a batch reactor feed water inlet 14, the water pipe 50 extends through the water valve 54 to the batch reactor feed water inlet 14, the water valve actuator 56 is in control communication with the water valve 54, and the data processor / storage unit 112 is in control communication with the water valve actuator 56, and step (c) comprises: (c') A method for batch process continuous application of the fire resistant composition according to item 11, further comprising controlling the input of water to the batch reactor 10 utilizing data from the data processor / storage unit 112, the water valve actuator 56, the water valve 54, and the product container contents sensor 66.

[0093] 13. A method for batch process continuous application of a fire resistant composition according to any of items 11 or 12, wherein the data processor / storage unit 112 enables the transfer of powder from the powder bin 30 to the batch reactor 10 and the input of water to the batch reactor 10 when the data processor / storage unit 112 determines that the batch reactor 10 is not filled, the product container 60 is capable of accommodating the product produced from the powder and water input to the batch reactor 10, and at least one of system initialization and spraying is occurring.

[0094] 14. The batch process continuous coating apparatus 2 further comprises a slurry pump 70 having an inlet and an outlet, the apparatus 2 further comprises a slurry pump regulator 72, the inlet of the slurry pump 70 communicating with the outlet of the product container 60 and the outlet of the slurry pump 70 communicating with the inlet of the nozzle 80, the slurry pump regulator 72 in control communication with the slurry pump 70, and the data processor / storage unit 112 in control communication with the slurry pump regulator 72, and step (d) comprises: operating the mixer 17 when the data processor / storage unit 122 determines that the slurry pump 70 is operating, the batch reactor 10 is filled, and the product vessel 60 is capable of accommodating the contents of the batch reactor 10; activating mixer 17 during system initialization when batch reactor 10 is filled and product vessel 60 is capable of accommodating the contents of batch reactor 10; pausing the mixer 17 when the data processor / storage unit 122 determines that the slurry pump 70 is running, the batch reactor 10 is filling, and the product vessel 60 cannot accommodate the contents of the batch reactor 10; stopping the mixer 17 when the data processor / storage unit 122 determines that the batch processing is complete; and stopping the mixer (17) when the data processing / storage unit (122) determines that the slurry pump (70) has stopped.

[0095] 15. The batch process continuous coating apparatus 2 further comprises a load measuring sensor 20 in sensing communication with the batch reactor 10, and a data processor / storage unit 112 in receiving communication with the load measuring sensor 20; 13. A method for batch process continuous application of a refractory composition according to item 12, wherein data from the load measuring sensor 20 is used to control the transfer of powder from the powder bin 30 to the batch reactor 10 for filling the batch reactor 10, and to control the supply of water to the batch reactor 10.

[0096] The present invention can comprise, consist of, or consist essentially of various features and characteristics described herein. In some cases, the present invention can also be essentially free of components or other features or characteristics described herein.

[0097] Also, any numerical range recited herein includes the recited endpoints and describes all subranges of the same numerical precision (i.e., having the same number of specified digits) encompassed within the recited range. For example, a recited range of "1.0 to 10.0" describes all subranges between (and including) the recited minimum value of 1.0 and the recited maximum value of 10.0, such as "2.4 to 7.6," even if the range "2.4 to 7.6" is not expressly recited within the body of the specification. Accordingly, the applicant reserves the right to amend this specification, including the claims, to explicitly recite any subrange of the same numerical precision encompassed within the ranges expressly recited herein. All such ranges are essentially described herein, such that an amendment to explicitly recite any such subranges would comply with the requirements of written description, sufficiency of description, and additional matter (e.g., U.S. Patent Act § 112(a) and EPC Article 123(2)).

[0098] As used herein, the grammatical articles "one," "a," "an," and "the" are intended to include "at least one" or "one or more," unless otherwise indicated or required by context. Thus, articles are used herein to refer to one or more than one (i.e., "at least one") grammatical object of the article. As an example, "component" means one or more components, and thus, more than one component is conceivable and may be employed or used in the implementation of the invention. Furthermore, unless otherwise required by the context of usage, the use of a singular noun includes the plural, and the use of a plural noun includes the singular.

Claims

1. A batch process continuous coating device (2), comprising: a powder bottle (30) having an outlet; a powder feed valve (38) located at the powder bin outlet; a powder feed valve regulator (40) in controlling communication with the powder feed valve (38); A batch reactor (10) comprising a feed inlet (12), a door (22), a batch reactor drive (16), a mixer (17), a batch reactor drive regulator (18), and a batch reactor door actuator (24), the outlet of the powder bin (30) communicates with the feed inlet (12) of the batch reactor; a batch reactor drive controller (18) in controlling communication with the batch reactor drive (16); a batch reactor drive (16) in mechanical communication with the mixer (17); a batch reactor (10) having a batch reactor door actuator (24) in controlled communication with the door (22); a product container (60) having a feed opening and a discharge opening, the feed opening of the product container (60) configured to receive the contents of the batch reactor (10) passing through a door (22); a product container contents sensor (66) adapted to sense the amount of contents (68) of the product container (60); a controller (100) comprising a data processor / storage unit (112), said data processor / storage unit (112) in receptive communication with said product container contents sensor (66), said data processor / storage unit (112) in control communication with said powder feed valve regulator (40), said data processor / storage unit (112) in control communication with said batch reactor drive regulator (18), and said data processor / storage unit (112) in control communication with said batch reactor door actuator (24); a nozzle (80) having an inlet and an outlet, the nozzle inlet receiving the outlet of the product container (60), the nozzle inlet receiving the outlet of an air hose (86), the flow of air in the air hose (86) being regulated by an air supply valve (88) and controlled by an air supply valve actuator (90); A water valve (54); a water pipe (50) that extends through a water valve (54) to the batch reactor water inlet (14) of the batch reactor (10); A batch process continuous coating apparatus (2) comprising: a water valve actuator (56), the water valve actuator (56) in controlling communication with a water valve (54), and a data processor / storage unit (112) in controlling communication with the water valve actuator (56).

2. a powder feeder (42) having an inlet and an outlet, the outlet of the powder bin (30) communicating with the inlet of the powder feeder (42) and the outlet of the powder feeder (42) communicating with the inlet (12) of the batch reactor (10); 2. The batch process continuous coating apparatus (2) of claim 1, further comprising a powder feeder regulator (44), the powder feeder regulator (44) in controlling communication with the powder feeder (42), and a data processor / storage unit (112) in controlling communication with the powder feeder regulator (44).

3. a slurry pump (70) having a supply inlet and a discharge outlet, the supply inlet of the slurry pump (70) communicating with the discharge outlet of a product container (60) and the discharge outlet of the slurry pump (70) communicating with the supply inlet of a nozzle (80); 3. The batch process continuous coating apparatus (2) of claim 1 or 2, further comprising a slurry pump regulator (72), the slurry pump regulator (72) in controlling communication with the slurry pump (70), and a data processor / storage unit (112) in controlling communication with the slurry pump regulator (72).

4. 4. The batch process continuous coating apparatus of claim 3, wherein the data processor / storage unit is configured to generate a ratio of a flow rate through the slurry pump and a flow rate through the air hose, and to maintain the ratio of the slurry pump flow rate and the air hose flow rate as the air hose flow rate changes.

5. 5. The batch process continuous coating apparatus (2) of claim 4, further comprising a water flow sensor (52) in sensing communication with the water pipe (50), the data processor / storage unit (112) being in receiving communication with the water flow sensor (52).

6. 6. The batch process continuous coating apparatus (2) of 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 drive regulator (18).

7. 7. The batch process continuous coating apparatus (2) of any one of claims 1 to 6, further comprising a load measuring sensor (20) in sensing association with the batch reactor (10), the data processor / storage unit (112) being in receiving association with the load measuring sensor (20).

8. a powder bin vibrator (32) associated with the powder bin (30); a powder bin vibrator actuator (34) in control communication with the powder bin vibrator (32); a product container vibration device (62) associated with the product container (60); The batch process continuous coating apparatus (2) of any one of claims 1 to 7, further comprising a product container vibration actuator (64), in controlled communication with the product container vibration device (62).

9. The batch process continuous coating apparatus (2) according to any one of claims 1 to 8, wherein the batch reactor drive (16) is configured to provide at least 7500 watts of mechanical power to the mixer (17).

10. 1. A method for batch process continuous application of a fire resistant composition comprising: (a) providing a batch process continuous coating apparatus (2) according to any one of claims 1 to 9; (b) providing instructions to a controller (100); (c) utilizing data from the data processor / storage unit (112), the powder feed valve regulator (40), and the powder feed valve (38), and the product container contents sensor (66), to control the transfer of powder from the powder bin (30) to the batch reactor (10) to fill the batch reactor (10); (d) utilizing data from the data processor / storage unit (112), the batch reactor drive controller (18), the batch reactor drive (16), and the product container contents sensor (66) to activate, control, and stop a mixer (17) in the batch reactor (10) for processing said powder to form a product; (e) utilizing data from a data processor / storage unit (112), a batch reactor door actuator (24), and the batch reactor door (22), and data from a product container contents sensor (66), delivering said product from the batch reactor (10) to a product container (60); (f) transferring said product from a product container (60) to a nozzle (80); (g) providing air to a nozzle (80); (h) combining said product with air in a nozzle (80); (i) spraying the combined air and product; (j) repeating steps (c), (d), and (e) to produce a continuous supply of product; the batch process continuous coating apparatus (2) further comprising a water pipe (50), a water valve (54), and a water valve actuator (56); the batch reactor (10) further comprises a batch reactor feed water inlet (14), the water pipe (50) extending through the water valve (54) to the batch reactor feed water inlet (14), the water valve actuator (56) in control communication with the water valve (54); and a data processor / storage unit (112) in control communication with the water valve actuator (56); and step (c) comprises: (c') The method for batch process continuous application of a fire resistant composition further comprising controlling water input to the batch reactor (10) utilizing data from the data processor / storage unit (112), the water valve actuator (56), the water valve (54), and the product container contents sensor (66).

11. 11. The method for batch process continuous application of a fire resistant composition as set forth in claim 10, wherein the data processor / storage unit (112) enables the transfer of powder from the powder bin (30) to the batch reactor (10) and the input of water to the batch reactor (10) when the data processor / storage unit (112) determines that the batch reactor (10) is not filled, that a product container (60) can accommodate the product produced from the powder and water input to the batch reactor (10), and that at least one of system initialization and spraying is occurring.

12. the batch process continuous coating apparatus (2) further comprising a slurry pump (70) having an inlet and an outlet, the apparatus (2) further comprising a slurry pump regulator (72), the inlet of the slurry pump (70) communicating with the outlet of the product container (60) and the outlet of the slurry pump (70) communicating with the inlet of the nozzle (80), the slurry pump regulator (72) in control communication with the slurry pump (70), and the data processor / storage unit (112) in control communication with the slurry pump regulator (72); and step (d) further comprising: operating the mixer (17) when the data processor / storage unit (112) determines that the slurry pump (70) is operating, the batch reactor (10) is filled, and the product vessel (60) is capable of accommodating the contents of the batch reactor (10); activating the mixer (17) during system initialization when the batch reactor (10) is filled and the product container (60) is capable of accommodating said contents of the batch reactor (10); pausing the mixer (17) when the data processor / storage unit (112) determines that the slurry pump (70) is running, the batch reactor (10) is filling, and the product vessel (60) cannot accommodate said contents of the batch reactor (10); stopping the mixer (17) when the data processor / storage unit (112) determines that the batch processing is complete; and stopping the mixer (17) when the data processor / storage unit (112) determines that the slurry pump (70) has stopped.

13. The batch process continuous coating apparatus (2) further comprises a load measurement sensor (20) in sensing communication with the batch reactor (10), and a data processor / storage unit (112) in receiving communication with the load measurement sensor (20); 13. The method for batch process continuous application of a fire-resistant composition according to any one of claims 10, 11 and 12, wherein data from a load measuring sensor (20) is used to control the transfer of powder from a powder bin (30) to a batch reactor (10) for filling the batch reactor (10) and to control the input of water to the batch reactor (10).

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