Slag and hot metal runner system

Claim 2

In a runner system for conveying molten slag across a pouring floor from a source of molten slag to a pouring point, the runner system including a trench means in the pouring floor for containing molten slag, the trench means including sides and a bottom, an improvement in combination therewith comprising: a replaceable liner means located in the trench means for forming a replaceable channel in the trench means, said replaceable liner means including a plurality of monolithic units, each monolithic unit having a bottom portion and wall portions, said wall portions being in abutting relationship with the trench means sides and said bottom portion resting on the trench means bottom and extending completely across the trench means bottom between said liner means wall portions whereby the trench means reinforces said monolithic unit; said monolithic units being unattached to each other or to the trench means to line the trench means with a plurality of unconnected and unattached monolithic units whereby any one of said plurality of monolithic units can be removed from the trench means without significantly disturbing either the trench means or any other monolithic unit.

Claim 3

The improvement defined in claim 1 wherein said monolithic units are formed of a plurality of materials including sinter alumina, silica carbide, fire clay, phosphoric acid and a binder that chemically reacts with the other materials.

Claim 4

The improvement defined in claim 1 wherein said monolithic unit wall portions extend from the trench means bottom upwardly for a significant portion of the distance between the trench means bottom and the top surface of the pouring floor.

Claim 5

The improvement defined in claim 2 wherein said binder includes sodium silicate.

Claim 6

The improvement set forth in claim 1 and wherein said monolithic units are formed of a coalesced mass of sinter alumina between about 20% to 60% by weight, silicon carbide between about 25% to 45% by weight, fine clay between about 10% to 45% by weight and a binder between about 10% to 20% by weight from a group consisting of sodium silicate and phosphoric acid and water to form a moldable mixture.

Claim 7

The improvement set forth in claim 1 and wherein said monolithic units are formed of a heat coalesced mass of a mixture consisting of sinter alumina 20% by weight, silicon carbide 25% by weight, fine clay 45% by weight and phosphoric acid 10% by weight and water to mix a desired consistency suitable for shaping.

Claim 8

The improvement set forth in claim 1 and wherein said monolithic units are formed of a vibratory force coalesced mass of a mixture consisting of sinter alumina 20% by weight, silicon carbide 25% by weight, fine clay 45% by weight and phosphoric acid 10% by weight and water to mix a desired consistency suitable for shaping.

Claim 9

The improvement set forth in claim 1 wherein said monolithic units are formed of a coalesced mass of a mixture consisting of sinter alumina between 20% to 50% by weight, silicon carbide between about 20% to 40% by weight, fine clay between about 10% and 40% by weight, metallic aluminum between about 20% and 30% by weight, and a binder between about 3% and 20% by weight from a group consisting of sodium silicate, phenolic resin, phosphoric acid and water to form a moldable mixture.

Claim 10

The improvement set forth in claim 1 and wherein said monolithic units are formed of a coalesced mass of a mixture consisting of sinter alumina 15% by weight, silicon carbide 20% by weight, fine clay 35% by weight, metallic aluminum 20% by weight and sodium silicate 10% by weight.

Claim 11

The improvement set forth in claim 1 wherein said monolithic units are formed of a coalesced mass of a mixture consisting of sinter alumina 15% by weight, silicon carbide 25% by weight, fine clay 30% by weight, metallic aluminum 20% by weight and phenolic resin 10% by weight.

Claim 12

In a runner system for a hot metal pouring floor, said runner system extending from a source of molten metal and molten slag to a pouring point thereof, said runner system comprising a substantially permanent elongated trough defining structure having fixed side and bottom portions positioned in said pouring floor, an improvement in combination therewith comprising: a replaceable means for lining the runner system, said means for lining said runner system consisting of a plurality of channel shaped and monolithic units each including side walls extending from the trough bottom portion upwardly for a significant portion of the distance between the trough bottom portion and a top surface of the pouring floor and a bottom section positioned on the trough defining structure bottom portion, each monolithic unit being unattached to any other unit or to the trench defining structure so that each unit can be removed from the trench defining structure without significantly disturbing any other unit or the trench defining structure, said monolithic units being formed of sinter alumina in a range from 20% to 60%, silicon carbide in a range from 25% to 45%, fine clay in a range from 10% to 35%, a binder selected from a group consisting of sodium silicate and phosphoric acid that reacts with the other materials, and water substantially 10% by weight, said side walls being positioned in said trough defining structure against the sides thereof to oppositely disposed relation to one another and said bottom section being positioned in said trough defining structure on the bottom portion thereof whereby said monolithic units reinforce said elongated trough defining structure and said plurality of monolithic units form a replaceable channel for said molten metal and molten slag.

Claim 13

In a runner system for a hot metal pouring floor, said runner system extending from a source of molten metal and molten slag to a pouring point thereof, said runner system comprising a substantially permanent elongated trough defining structure having fixed side and bottom portions positioned in said pouring floor, an improvement in combination therewith comprising: a replaceable means for lining the runner system, said means for lining said runner system consisting of a plurality of channel shaped and monolithic units each including side walls extending from the trough bottom portion upwardly for a significant portion of the distance between the trough bottom portion and a top surface of the pouring floor and a bottom section positioned on the trough defining structure bottom portion, each monolithic unit being unattached to any other unit or to the trench defining structure so that each unit can be removed from the trench defining structure without significantly disturbing any other unit or the trench defining structure, said monolithic units being formed of sinter alumina in a range from 20% to 60%, silicon carbide in a range from 25% to 45%, fine clay in a range from 10% to 35%, a binder selected from a group consisting of sodium silicate and phosphoric acid that reacts with the other materials, and water substantially 10% by weight, said side walls being positioned in said trough defining structure against the sides thereof to oppositely disposed relation to one another and said bottom section being positioned in said trough defining structure on the bottom portion thereof whereby said monolithic units reinforce said elongated trough defining structure and said plurality of monolithic units form a replaceable channel for said molten metal and molten slag.

Claim 14

The improvement defined in claim 11 wherein each of said monolithic units is in abutting relationship which an adjacent monolithic unit.

Claim 15

The improvement set forth in claim 11 wherein said elongated trough defining structure has base slabs of hydraulically bonded high alumina content refractory and prefabricated side walls of hydraulically bonded high alumina concrete on and against which said preformed liner units are positioned, said liner units supported on said base slab.

Claim 16

The improvement set forth in claim 11 wherein said trough defining structure has a concrete base slab, transversely spaced side wall portions formed of refractory bricks positioned thereon, a secondary slab formed of hydraulically bonded high alumina concrete on said base slab, secondary side walls formed of hydraulically bonded high alumina concrete on said secondary slab in oppositely disposed relation and against said refractory brick side walls, longitudinally extending concrete curbs on said side walls defining with said secondary slab said elongated trough structure and said liner units are positioned in said elongated trough structure against said secondary sidewalls thereof on said secondary slab.

Claim 17

The improvement set forth in claim 14 and wherein the overall height of said side wall portions of hydraulically bonded high alumina concrete and said concrete curbs is greater than the height of said monolithic liner units.