Refractory composition comprising nitride filler and colloidal sol binder

Claim 1

A refractory composition having high resistance to corrosion by molten metal chlorides and chlorine gas at elevated temperatures, said composition comprising (a) about 100 parts by weight of a nitride refractory filler selected from the group consisting of nitrides of silicon, aluminum, titanium, chromium, hafnium, zirconium, beryllium, magnesium, manganese, iron, scandium, yttrium and rare earth elements; silicon oxynitride; aluminum oxynitride; and silicon aluminum oxynitride wherein the aluminum and oxygen are in a solid solution of silicon nitride; (b) about 30 to 100 parts by weight of a colloidal sol binder selected from the group consisting of silica, silicon aluminum oxynitride wherein the aluminum and oxygen are in a solid solution of silicon nitride, silicon oxynitride, silicon nitride, aluminum nitride, boron nitride and alumina, all in colloidal sol form, said binder comprising an aqueous suspension containing up to about 50 wt.% solids, the quantity of binder and the concentration of binder solids being sufficient to coat substantially all of the filler and to form a plastic mixture with the filler; and (c) less than about 2 parts by weight of the oxides or hydroxides of magnesium, calcium, chromium and manganese.

Claim 15

A method for joining refractory bricks comprising the steps of: (a) preparing a mortar mix comprising: (i) about 100 parts by weight of a particulate nitride refractory filler selected from the group consisting of nitrides of silicon, aluminum, titanium, chromium, hafnium, zirconium, beryllium, magnesium, and manganese, iron, scandium, yttrium and rare earth elements; silicon oxynitride; aluminum oxynitride and silicon aluminum oxynitride wherein the aluminum and oxygen are in a solid solution of silicon nitride, substantially all of said particulate filler passing through a 48 mesh screen (Tyler Series); (ii) about 30 to 100 parts by weight, based on the weight of the filler, of a colloidal sol binder and the concentration of binder solids selected from the group consisting of silica, silicon aluminum oxynitride. wherein the aluminum and oxygen are in a solid solution of silicon nitride, silicon nitride, silicon oxynitride, aluminum nitride, boron nitride and alumina, all in colloidal sol form, said binder comprising an aqueous suspension containing up to about 50 wt.% solids, the quantity of binder being sufficient to coat substantially all of the filler particles and to form a plastic mixture with the filler; and (iii) less than about 2 parts by weight of the oxides or hydroxides of magnesium, calcium, chromium and manganese; (b) applying the mortar mix to form a seam between a pair of opposed refractory bricks, said seam and bricks comprising, in combination, a refractory assembly; and (c) firing the refractory assembly at an elevated temperature of about 700° to 800° C.

Claim 16

A method for joining refractory bricks comprising the steps of: (a) preparing a mortar mix comprising: (i) about 100 parts by weight of a particulate nitride refractory filler selected from the group consisting of nitrides of silicon, aluminum, titanium, chromium, hafnium, zirconium, beryllium, magnesium, and manganese, iron, scandium, yttrium and rare earth elements; silicon oxynitride; aluminum oxynitride and silicon aluminum oxynitride wherein the aluminum and oxygen are in a solid solution of silicon nitride, substantially all of said particulate filler passing through a 48 mesh screen (Tyler Series); (ii) about 30 to 100 parts by weight, based on the weight of the filler, of a colloidal sol binder and the concentration of binder solids selected from the group consisting of silica, silicon aluminum oxynitride. wherein the aluminum and oxygen are in a solid solution of silicon nitride, silicon nitride, silicon oxynitride, aluminum nitride, boron nitride and alumina, all in colloidal sol form, said binder comprising an aqueous suspension containing up to about 50 wt.% solids, the quantity of binder being sufficient to coat substantially all of the filler particles and to form a plastic mixture with the filler; and (iii) less than about 2 parts by weight of the oxides or hydroxides of magnesium, calcium, chromium and manganese; (b) applying the mortar mix to form a seam between a pair of opposed refractory bricks, said seam and bricks comprising, in combination, a refractory assembly; and (c) firing the refractory assembly at an elevated temperature of about 700° to 800° C.