Stable refractory slurry composition

Claim 2

A SUSPENDING AGENT SYSTEM USEFUL FOR SUSPENDING REFRAC: TORY GRAINS COMPRISING (A) CARBOXYMETHYL CELLULOSE AND (B9 A WATER-SOLUBLE CARBOXYVINYL POLYMER HAVING A MOLECULAR WEIGHT WITHIN THE RANGE OF ABOUT 250,000 TO 4,000,000 IN A TOTAL AMOUNT OF ABOUT 36 TO 65 WEIGHT PERCENT WITH THE RELATIVE AMOUNT OF (A) TO (B) VARYING FROM A WEIGHT PERCENT RATIO OF ABOUT 1:4 TO 4:1 AND (C) MAGNESIUM MONTMORILLONITE CLAY IN A CONCENTRATION OF ABOUT 35 TO 64 WEIGHT PERCENT.

Claim 3

A binder vehicle concentrate for a silicious refractory slurry composition useful for coating heat sensitive surfaces comprising from about 20 to 32 percent by weight colloidal silica; a three component suspending agent system comprising (a) carboxymethyl cellulose and (b) a water-soluble carboxyvinyl polymer having a molecular weight within the range of about 250, 000 to 4,000,000 in a total amount of about 0.45 to 0.55 percent by weight with the relative amount of (a) to (b) varying from a weight percent ratio of about 1:4 to 4:1 and (c) magnesium montmorillonite from 0.30 to 0.80 percent by weight; 0 to 0.20 percent by weight of a base selected from the group consisting of sodium hydroxide, potassium hydroxide and ammonium hydroxide; and the remainder being water; said weight percentages being based upon the total weight of the binder vehicle concentrate.

Claim 4

A binder vehicle concentrate for a silicious refractory slurry composition useful for coating heat sensitive surfaces comprising from about 20 to 32 percent by weight colloidal silica; a three component suspending agent system comprising (a) carboxymethyl cellulose and (b) a water-soluble carboxyvinyl polymer having a molecular weight within the range of about 250, 000 to 4,000,000 in a total amount of about 0.45 to 0.55 percent by weight with the relative amount of (a) to (b) varying from a weight percent ratio of about 1:4 to 4:1 and (c) magnesium montmorillonite from 0.30 to 0.80 percent by weight; 0 to 0.20 percent by weight of a base selected from the group consisting of sodium hydroxide, potassium hydroxide and ammonium hydroxide; and the remainder being water; said weight percentages being based upon the total weight of the binder vehicle concentrate.

Claim 5

Adding the base as a dilute solution in sufficient amount to bring the pH of the solution of suspending agents to between 5 to 9;

Claim 6

Adding the base as a dilute solution in sufficient amount to bring the pH of the solution of suspending agents to between 5 to 9;

Claim 7

Adding colloidal silica sol and using moderate to high shear mixing to render the solution uniform; and

Claim 8

Adding colloidal silica sol and using moderate to high shear mixing to render the solution uniform; and

Claim 9

A stable, silicious, refractory slurry composition useful for coating heat sensitive surfaces comprising refractory silica dispersed in a colloidal silica binder vehicle concentrate and water, the ratio of the refractory silica to said binder vehicle concentrate to water being about 1:1:1 on a weight basis; said binder vehicle concentrate containing about 20 to 32 percent by weight colloidal silica; a three component suspending agent system comprising (a) carboxymethyl cellulose and (b) a water-soluble carboxyvinyl polymer having a molecular weight within the range of about 250,000 to 4,000,000 in a total amount of about 0.45 to 0.55 percent by weight with the relative amount of (a) to (b) varying in a weight percent ratio of about 1:4 to 4:1 and (c) about 0.30 to 0.80 weight percent of magnesium montmorillonite clay; 0 to 0.20 percent by weight of a base selected from the group consisting of sodium hydroxide, potassium hydroxide and ammonium hydroxide; and the remainder being water, wherein for all components of the binder vehicle concentrate said weight percentages are based upon the total weight of the binder vehicle concentrate.

Claim 10

A stable, silicious, refractory slurry composition useful for coating heat sensitive surfaces comprising refractory silica dispersed in a colloidal silica binder vehicle concentrate and water, the ratio of the refractory silica to said binder vehicle concentrate to water being about 1:1:1 on a weight basis; said binder vehicle concentrate containing about 20 to 32 percent by weight colloidal silica; a three component suspending agent system comprising (a) carboxymethyl cellulose and (b) a water-soluble carboxyvinyl polymer having a molecular weight within the range of about 250,000 to 4,000,000 in a total amount of about 0.45 to 0.55 percent by weight with the relative amount of (a) to (b) varying in a weight percent ratio of about 1:4 to 4:1 and (c) about 0.30 to 0.80 weight percent of magnesium montmorillonite clay; 0 to 0.20 percent by weight of a base selected from the group consisting of sodium hydroxide, potassium hydroxide and ammonium hydroxide; and the remainder being water, wherein for all components of the binder vehicle concentrate said weight percentages are based upon the total weight of the binder vehicle concentrate.

Claim 11

A composition of claim 3 having as an additional component a water soluble polyhydric aliphatic compound compatible with the colloidal silica present in amounts from about 6 to 40 weight percent based upon the total weight of the binder vehicle concentrate.

Claim 12

Diluting with water, adding refractory silica and using low to moderate shear mixing to accomplish dispersion.

Claim 13

Diluting with water, adding refractory silica and using low to moderate shear mixing to accomplish dispersion.

Claim 14

A composition of claim 4 wherein the polyhydric aliphatic compound is ethylene glycol.

Claim 15

A refractory slurry composition of claim 3 wherein the refractory silica consists of 30 to 50 weight percent vitreous silica and from 50 to 70 percent by weight crystalline silica.

Claim 16

A stable silicious, refractory slurry composition of claim 6 wherein the binder vehicle concentrate is comprised of about 0.2 to 0.3 weight percent of carboxymethyl cellulose, about 0.3 to 0.2 weight percent of a water-soluble carboxyvinyl polymer having a molecular weight within the range of about 250,000 to 4,000, 000, about 0.4 to 0.6 weight percent of magnesium montmorillonite clay, about 50 to 70 weight percent of a colloidal silica sol having 40 percent by weight colloidal silica, About 0.08 to 0.12 weight percent of sodium hydroxide, about 6 to 10 weight percent of ethylene glycol, about 0.02 to 0.05 weight percent of nonionic or anionic wetting agent, about 0.01 to 0.03 weight percent of an antifoam agent, and about 0.03 to 0.07 weight percent of formaldehyde; the remainder being water.

Claim 17

A stable, silicious, refractory slurry composition of claim 3 having a low viscosity within the range of 800-1,500 cps.

Claim 18

A process of making a composition of claim 8 comprising the following steps: