Harbison-walker Refractories Company

Westmoreland Advanced Materials, Inc.

Indresco Inc.

Robert M Cullen

Kenneth A McGowan

Xiangmin Li

James Gordon Hemrick

Roberta A Meisner

James R Keiser

James G Hemrick

A method for improving the insulating character/and or penetration resistance of a surface comprising lining a surface of a lime kiln, a cement kiln, a roasting kiln, a thermal oxidizer, or a fluidized bed reactor that is subject to wear by an alkali environment and/or an alkaline environment with a refractory composition comprising a refractory aggregate consisting essentially of a calcium hexa aluminate clinker having the formula CA, wherein C is equal to calcium oxide, wherein A is equal to aluminum oxide, and wherein the hexa aluminate clinker has from zero to less than about fifty weight percent CA, and wherein greater than 98 weight percent of the calcium hexa aluminate clinker having a particle size ranging from &#x2212;20 microns to +3 millimeters, for forming a liner of the surface.

Methods of use of calcium hexa aluminate refractory linings and/or chemical barriers in high alkali or alkaline environments

A method for improving the insulating character/and or penetration resistance of a liner in contact with at least one of an alkali and/or alkaline environments is provided. The method comprises lining a surface that is subject to wear by an alkali environment and/or an alkaline environment with a refractory composition comprising a refractory aggregate consisting essentially of a calcium hexa aluminate clinker having the formula CA, wherein C is equal to calcium oxide, wherein A is equal to aluminum oxide, and wherein the hexa aluminate clinker has from zero to less than about fifty weight percent CA, and wherein greater than 98 weight percent of the calcium hexa aluminate clinker having a particle size ranging from &#x2212;20 microns to +3 millimeters, for forming a liner of the surface. This method improves the insulating character/and or penetration resistance of the liner.

An essentially non-slumping sprayable refractory castable composition that is applied without forms is disclosed comprising (a) a tempered, pumpable first component comprising (i) one hundred weight percent of a refractory composition comprising from about 60 to 90 weight percent of a refractory aggregate, from about 2 to 25 weight percent of an ultrafine refractory material having an average particle diameter size less than or equal to about 3 microns, from about 0.5 to 15 weight percent of a binder, and from about 0.05 to 2.0 weight percent of a dispersant, wherein all or a portion of the ultrafine refractory material comprises a thermal black such that the refractory composition comprises from about 2 to 15 weight percent of the thermal black, and (ii) from about 3 to 10 weight percent water based upon 100 weight percent of the refractory composition; and (b) a second component comprising a flocculating agent, wherein the second component is added to the first component for achieving installation of the sprayable refractory castable composition in an amount to prevent slumping. A method of installing the sprayable refractory castable composition is also disclosed.

Non-slumping sprayable refractory castables containing thermal black

A refractory castable composition is disclosed comprising one hundred weight percent of a refractory composition comprising from about 60 to 90 weight percent of a refractory aggregate, from about 2 to 25 weight percent of an ultrafine refractory material having an average particle diameter size less than or equal to about 3 microns, from about 0.5 to 15 weight percent of a binder, and from about 0.05 to 2.0 weight percent of a dispersant, wherein all or a portion of the ultrafine refractory material comprises a thermal black such that the refractory composition comprises from about 2 to 15 weight percent of the thermal black, and from about 3 to 10 weight percent water based upon 100 weight percent of the refractory composition, and wherein the water is present in an amount sufficient to achieve a castable consistency. A method of installing the refractory castable composition is also disclosed.

Refractory castables containing thermal black

A magnesium electrolysis cell having a refractory lining comprising at least one glass-ceramic shape, the lining itself, and the method of increasing the service life of the refractory lining of a magnesium electrolysis cell comprising using a plurality of glass-ceramic shapes to form the lining.

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Bethel Park, PA, United States of America

Robert M Cullen