Method of making monolithic refractory lining in metallurgical vessels

Claim 1

A METHOD OF MAKING A CHEMICALLY BASIC REFRACTORY MONOLITH COMPRISING THE STEPS OF: (1) COMBINING A DRY SOLIDS BATCH MIXTURE OF, (A) AT LEAST ABOUT 90%, BY WEIGHT, OF GRANULAR DEAD BURNED MAGNESITE SIZED SUCH THAT 30 TO 70%, BY WEIGHT, IS ABOUT -3 +28 MESH AND ABOUT 70 TO 30%, BY WEIGHT, PASSES A 65 MESH SCREEN, (B) 1 TO 10%, BY WEIGHT, OF POWDER SODIUM SILICATE CAPABLE OF REACTING WITH MAGNESITE WHICH PASSES THE 65 MESH SCREEN TO SET THE BATCH WHEN IT IS TEMPERED, (C) UP TO ABOUT 5%, BY WEIGHT, OF PLASTICIZING AGENT SELECTED FROM THE GROUP CONSISTING ESSENTIALLY OF KAOLINITIC AND MONTMORILLONITIC CLAY AND VOLATILIZED SILICA, (D) THE CHEMICAL ANALYSIS ON AN OXIDE BASIS OF THE BATCH BEING AT LEAST ABOUT 90%, BY WEIGHT, MGO, (2) AND TEMPERING WITH ABOUT 3 TO 10%, BY WEIGHT, OF AN AQUEOUS TEMPERING AGENT, BASED ON THE TOTAL WEIGHT OF THE DRY SOLIDS IN THE BATCH, (3) EMPLACING THE TEMPERED BATCH INTO THE SITUS OF USE, (4) ALLOWING THE EMPLACED MATERIAL TO SET FOR A TIME PERIOD SUFFICIENT FOR AT LEAST THE UPPER SURFACE TO DRY OUT AND BECOME HARD AND ROCK-LIKE AND CHARACTERIZED BY WHITENING AND A MATTE APPEARANCE, (5) RETEMPERING THE EMPLACED MATERIAL WITH ADDITIONAL AQUEOUS TEMPERING AGENT IN A QUANTITY SUFFICIENT TO OBTAIN A SUBSTANTIALLY UNIFORM WATER CONTENT FROM TOP TO BOTTOM, AND (6) IMMEDIATELY SUBJECTING THE EMPLACED MATERIAL TO BURN-IN.

Claim 2

A METHOD OF MAKING A CHEMICALLY BASIC REFRACTORY MONOLITH COMPRISING THE STEPS OF: (1) COMBINING A DRY SOLIDS BATCH MIXTURE OF, (A) AT LEAST ABOUT 90%, BY WEIGHT, OF GRANULAR DEAD BURNED MAGNESITE SIZED SUCH THAT 30 TO 70%, BY WEIGHT, IS ABOUT -3 +28 MESH AND ABOUT 70 TO 30%, BY WEIGHT, PASSES A 65 MESH SCREEN, (B) 1 TO 10%, BY WEIGHT, OF POWDER SODIUM SILICATE CAPABLE OF REACTING WITH MAGNESITE WHICH PASSES THE 65 MESH SCREEN TO SET THE BATCH WHEN IT IS TEMPERED, (C) UP TO ABOUT 5%, BY WEIGHT, OF PLASTICIZING AGENT SELECTED FROM THE GROUP CONSISTING ESSENTIALLY OF KAOLINITIC AND MONTMORILLONITIC CLAY AND VOLATILIZED SILICA, (D) THE CHEMICAL ANALYSIS ON AN OXIDE BASIS OF THE BATCH BEING AT LEAST ABOUT 90%, BY WEIGHT, MGO, (2) AND TEMPERING WITH ABOUT 3 TO 10%, BY WEIGHT, OF AN AQUEOUS TEMPERING AGENT, BASED ON THE TOTAL WEIGHT OF THE DRY SOLIDS IN THE BATCH, (3) EMPLACING THE TEMPERED BATCH INTO THE SITUS OF USE, (4) ALLOWING THE EMPLACED MATERIAL TO SET FOR A TIME PERIOD SUFFICIENT FOR AT LEAST THE UPPER SURFACE TO DRY OUT AND BECOME HARD AND ROCK-LIKE AND CHARACTERIZED BY WHITENING AND A MATTE APPEARANCE, (5) RETEMPERING THE EMPLACED MATERIAL WITH ADDITIONAL AQUEOUS TEMPERING AGENT IN A QUANTITY SUFFICIENT TO OBTAIN A SUBSTANTIALLY UNIFORM WATER CONTENT FROM TOP TO BOTTOM, AND (6) IMMEDIATELY SUBJECTING THE EMPLACED MATERIAL TO BURN-IN.