Vibratable refractory mix and binder therefor

Claim 2

A vibratable refractory mix comprising the following components: (a) a particulate, non-basic refractory grain material in an amount sufficient and a sizing suitable to provide refractoriness to said mix, (b) a P 2 O 5 source in an amount sufficient to form a bond with said non-basic refractory material, (c) a non-clay containing binder which comprises a blend of a member selected from the group consisting of a cellulose ether, microcrystalline cellulose and polyvinyl alcohol in an amount sufficient to provide slump resistance to said mix after it has been vibrated into a form and the form is removed, and a dry, colloidal, particulate material in an amount sufficient to reduce phosphate migration in said mix, after it has been vibrated into a form and cured by heating, to a maximum acceptable level to achieve satisfactory integrity of the molded refractory product, and (d) water in an amount sufficient to provide lubricity to said mix and make it vibratable, but not in an amount which would adversely affect the slump resistance of said mix after it has been vibrated into a form.

Claim 3

A vibratable refractory mix according to claim 1 in which the particulate non-basic refractory grain material is selected from grains of alumina-silica, silicon carbide, magnesium-alumina-spinel, zircon, zirconia and alumina-chrome oxide.

Claim 4

A vibratable refractory mix according to claim 2 in which the particulate non-basic refractory grain material is alumina-silica.

Claim 5

A vibratable refractory mix according to claim 3 in which said grains comprise about 40 to about 75 percent coarse grains in the range of about 3-200 mesh and about 25 to about 60 percent fine grains of -325 mesh.

Claim 6

A vibratable refractory mix according to claim 1 in which the P 2 O 5 source is selected from phosphoric acid, monoaluminum phosphate and monoammonium phosphate.

Claim 7

A vibratable refractory mix according to claim 5 in which the P 2 O 5 source is phosphoric acid.

Claim 8

A vibratable refractory mix according to claim 1 in which the P 2 O 5 source is present in an amount of about 0.5 to about 14 percent based on the weight of particulate refractory material in the mix.

Claim 9

A vibratable refractory mix according to claim 1 in which the binder member to provide slump resistance is microcrystalline cellulose.

Claim 10

A vibratable refractory mix according to claim 1 in which the binder member to provide slump resistance is polyvinyl alcohol.

Claim 11

A vibratable refractory mix according in to claim 1 in which the binder member to provide slump resistance is a cellulose ether.

Claim 12

A vibratable refractory mix according to claim 10 in which water is incorporated with said cellulose ether.

Claim 13

A vibratable refractory mix according to claim 10 in which said cellulose ether is selected from methylcellulose, ethylcellulose, hydroxypropyl methylcellulose and hydroxybutyl methylcellulose.

Claim 14

A vibratable refractory mix according to claim 12 in which said cellulose ether is methylcellulose.

Claim 15

A vibratable refractory mix according to claim 13 in which the methylcellulose is present in an amount equal to about 0.1 to about 10 percent based on the total weight of said binder component.

Claim 16

A vibratable refractory mix according to claim 12 in which said cellulose ether is present in an amount equal to about 0.0005 to about 60 percent based on the total weight of said binder component.

Claim 17

A vibratable refractory mix according to claim 1 in which the binder member to reduce phosphate migration is selected from fumed silica, colloidal silicon carbide and colloidal magnesia-alumina spinel.

Claim 18

A vibratable refractory mix according to claim 16 in which said member is fumed silica.

Claim 19

A vibratable refractory mix according to claim 17 in which the fumed silica is present in an amount equal to about 40 to about 99.9 percent based on the total weight of said binder component.

Claim 20

A vibratable refractory mix according to claim 18 in which the fumed silica is present in an amount equal to about 80 to about 99 percent based on the total weight of said binder component.

Claim 21

A vibratable refractory mix according to claim 1 in which said binder component is present in an amount of about 0.1 to about 10 percent based on the weight of the particulate non-basic refractory material in the mix.

Claim 22

A vibratable refractory mix according to claim 1 in which water is present in an amount of about 2 to about 15 parts per 100 parts by weight of the particulate non-basic refractory material.

Claim 23

A vibratable refractory mix according to claim 1 in which (a) the particulate non-basic refractory grain material is grains of alumina-silica comprising about 40 to about 75 percent coarse grains in the range of about 3-200 mesh and about 25 to about 60 percent fine grains of -325 mesh, (b) the P 2 O 5 source is phosphoric acid present in an amount based on the total dry weight of the mix to about 0.5 to about 14 percent, (c) the binder component is present in an amount of about 2 to about 8 percent based upon the weight of the particulate refractory material in said mix, (d) the binder member to provide slump resistance is methyl-cellulose which is present in an amount from about 0.1 to about 10 weight percent based on the total weight of said binder component, (e) the binder member to reduce phosphate migration is fumed silica present in an amount from about 80 to about 99 percent based on the total weight of said binder component, (f) said binder component includes a deflocculating agent in an amount from about 0 to about 35 percent based on the total weight of said binder component, and (g) the water is present in an amount from about 2 to about 15 parts per 100 parts by weight of the alumina-silica.

Claim 24

A vibratable refractory mix according to claim 22 in which the deflocculating agent is sodium hexametaphosphate which is present in an amount between about 0 and about 5 percent based on the total weight of said binder component.