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Title:
REFRACTORY PRODUCTS AND THEIR MANUFACTURE
Document Type and Number:
WIPO Patent Application WO/2000/032539
Kind Code:
A2
Abstract:
A method of producing a refractory product comprising (a) preparing a foamed particulate ceramic composition from a particulate ceramic composition; (b) shaping the foamed ceramic composition into a shaped pre-fired article; and (c) firing the pre-fired article to produce a refractory product.

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WO/1989/000153METHOD FOR PRODUCING OF CONCRETE WITH VARIABLE DENSITY
WO/1997/025291FIRE PROOFING FOAM COMPOUND
Inventors:
FORBES NEIL ROBERT (GB)
HEARLE JONATHAN ANDREW (GB)
Application Number:
PCT/GB1999/003959
Publication Date:
June 08, 2000
Filing Date:
November 29, 1999
Export Citation:
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Assignee:
ECC INT LTD (GB)
FORBES NEIL ROBERT (GB)
HEARLE JONATHAN ANDREW (GB)
International Classes:
C04B38/10; F27D1/00; F27D5/00; (IPC1-7): C04B38/00
Domestic Patent References:
WO1989005285A11989-06-15
Foreign References:
US4824810A1989-04-25
EP0451928A11991-10-16
US4575439A1986-03-11
GB2212799A1989-08-02
GB2271987A1994-05-04
Attorney, Agent or Firm:
Mccormack, Derek James (ECC International Ltd. Intellectual Property Dept. John Keay House St. Austell Cornwall PL25 4DJ, GB)
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Claims:
CLAIMS
1. A method of producing a refractory product comprising (a) preparing a foamed particulate ceramic composition from a particulate ceramic composition; (b) shaping the foamed ceramic composition into a shaped prefired article; and (c) firing the prefired article to produce a refractory product.
2. A method according to claim 1, wherein step (a) further comprises preparing the foamed particulate ceramic composition from an aqueous mixture comprising the particulate ceramic composition.
3. A method according to claim 1 or 2, wherein step (b) further comprises extruding the foamed ceramic composition into a shaped configuration.
4. A method according to claim 3, wherein step (b) further comprises breaking or dividing the shaped configuration of extruded ceramic composition into pellets or prills.
5. A method according to claim 4, wherein step (b) further comprises drying the pellets or prills at a temperature of from 50°C to 200°C.
6. A method according to claim 3,4 or 5, wherein step (b) further comprises charging the foamed ceramic composition into a shaped mould to produce the shaped prefired article.
7. A method according to claim 6, further comprising applying a compacting pressure of at least 0.1 MPa to the foamed ceramic composition in the shaped mould.
8. A method according to claim 5, wherein the pellets or prills in a selected size range are selected to produce the shaped prefired article.
9. A method according to any one of the preceding claims, wherein the ceramic composition comprises granules comprising particles of inorganic materials.
10. A method according to claim 9, wherein a binder is employed to bind together the granules of the foamed ceramic composition.
11. A method according to any one of the preceding claims, wherein the firing in step (c) is carried out at a temperature of at least 1000°C for at least 2 hours and the granules of the foamed ceramic composition of the prefired article contain ingredients which react together to produce mullite and/or cordierite by such firing.
12. A method according to claim 11, wherein the firing is carried out at a temperature of from 1200°C to 1500°C for at least 2 hours.
13. A method according to any one of the preceding claims, wherein the foamed ceramic composition comprises a source of alumina, a source of magnesia and a source of silica.
14. A method according to claim 13, wherein the source of silica comprises an aluminosiliceous clay.
15. A method according to claim 13 or 14, wherein the foamed ceramic composition also comprises a mullitecontaining aluminosiliceous material.
16. A method according to any one of the preceding claims, wherein the foamed ceramic composition comprises from about 20% to about 50% by weight of kaolin clay and from about 30% to about 70% by weight of a mulliterich aluminosilicate material.
17. A method according to any one of claims 13 to 15, wherein the inorganic materials of the foamed ceramic composition comprises mulliterich aluminosilicate material at about 40 to about 60 parts by weight, kaolin clay at about 25 to about 35 parts by weight, alumina powder at about 8 to about 16 parts by weight, and talc at about 10 to about 15 parts by weight.
18. A method according to claim 17, wherein the kaolin clay is china clay or ball clay.
19. A method according to claim 15,16 or 17, wherein the mullitecontaining aluminosiliceous material contains at least 50% by weight mullite.
20. A method according to any one of claims 9 to 19, wherein the granules of the foamed ceramic composition have an average size of from 0. lmm to 10mm prior to charging in the mould.
21. A method according to any one of the preceding claims, wherein the foamed granular ceramic composition produced by the method has a bulk density of less than 2000kg. m~3.
22. A refractory product produced by the method according to any one of claims 1 to 21.
23. A product according to claim 22 which is an article of kiln furniture.
24. A product according to claim 22 or 23, which has a density of less than 2000kg. m3.
25. A product according to claim 22,23 or 24 which comprises the foamed ceramic composition comprising cordierite and mullite having a weight ratio of cordierite to mullite in the range 5: 95 to 95: 5.
Description:
INTERNATIONAL SEARCH REPORT Intetnational Appilcation No Pb,/GB 99/03959 C. (Continuation) DOCUMENTS CONSIDERED TO BE RELEVANT Category ° Citation of document, with indication, where appropriate, of the relevant passages Relevant to claim No. X US 4 575 439 A (HINTZEN ULLRICH ET AL) 1, 2, 11 March 1986 (1986-03-11) 22-24 column 1, line 9-line 17 column 1, line 61-column 2, line 20 column 2, line 65-column 3, line 6 examples 1-15 Y3-21,25 X WO 89 05285 A (DURIRON CO) 1,2, 15 June 1989 (1989-06-15) 22-24 claims 12,13; example 8 page 33, line 23-page 34, line 32 page 3, line 7-page 5, line 24 Y3-21,25 A GB 2 212 799 A (DURIRON CO) 1-21 2 August 1989 (1989-08-02) claim 1 examples1,2,5,6 A GB 2 271 987 A (ECC INT LTD) 1-25 4 May 1994 (1994-05-04) cited in the application claims1,2,8,9,11,18-20 example_ 1 INTERNATIONAL SEARCH r | Intew-ational Appllcation No nformation on patent family members PL./GB 99/03959 Patent document Publication Patent family Publication cited in search report date member (s) date US 4824810 A 25-04-1989 DE 3414965 A 02-01-1986 AT 46311 T 15-09-1989 AU 571060 B 31-03-1988 AU 3936185 A 15-11-1985 WO 8504862 A 07-11-1985 EP 0182793 A 04-06-1986 JP 3072035 B 15-11-1991 JP 61501907 T 04-09-1986 US 5032549 A 16-07-1991 EP 0451928 A 16-10-1991 DE 4011254 C 20-06-1991 AT 106662 T 15-06-1994 AU 633418 B 28-01-1993 AU 7464191 A 30-10-1991 CA 2051807 A 06-10-1991 CS 9100900 A 15-10-1991 WO 9115112 A 17-10-1991 DE 59101824 D 14-07-1994 HU 66466 A, B 28-11-1994 JP 4507047 T 10-12-1992 PL 166411 B 31-05-1995 RU 2074139 C 27-02-1997 US 4575439 A 11-03-1986 DE 3326270 A 07-02-1985 BE 900093 A 05-11-1984 FR 2549467 A 25-01-1985 GB 2143517 A, B 13-02-1985 IT 1174172 B 01-07-1987 WO 8905285 A 15-06-1989 US 4846906 A 11-07-1989 US 4871495 A 03-10-1989 US 4812424 A 14-03-1989 US 4814300 A 21-03-1989 US 4963515 A 16-10-1990 CA 1336582 A 08-08-1995 DE 3853002 D 23-03-1995 DE 3853002 T 05-10-1995 EP 0344284 A 06-12-1989 ES 2009421 A 16-09-1989 GB 2213140 A, B 09-08-1989 JP 2502374 T 02-08-1990 JP 2617362 B 04-06-1997 KR 9606252 B 11-05-1996 MX 169628 B 14-07-1993 CA 1315809 A 06-04-1993 GB 2213139 A, B 09-08-1989 US 4878947 A 07-11-1989 DE 3816893 A 15-06-1989 GB 2212799 A, B 02-08-1989 GB 2248833 A, B 22-04-1992 US 4976760 A 11-12-1990 DE 3816892 A 15-06-1989 GB-2216115 A, B 04-10-1989 CN 1034192 A 26-07-1989 GB 2213141 A, B09-08-1989 GB 2212799 A 02-08-1989 US 4871495 A 03-10-1989 CA 1336582 A 08-08-1995 INTERNATIONAL SEARCH ------------------- ! International Application No formation on patent family members Pl, /GB 99/03959 Patent document Publication Patent family Publication cited in search report date member (s) date GB 2212799 A DE 3816893 A 15-06-1989 DE 3853002 D 23-03-1995 DE 3853002 T 05-10-1995 EP 0344284 A 06-12-1989 ES 2009421 A 16-09-1989 GB 2248833 A, B 22-04-1992 JP 2502374 T 02-08-1990 JP 2617362 B 04-06-1997 KR 9606252 B 11-05-1996 MX 169628 B 14-07-1993 W0 8905285 A 15-06-1989 US 4976760 A 11-12-1990 GB 2271987 A 04-05-1994 AT 168670 T 15-08-1998 DE 69319839 D 27-08-1998 DE 69319839 T 03-12-1998 EP 0595543 A 04-05-1994 ES 2118907 T 01-10-1998 JP 6191965 A 12-07-1994 US 5418195 A 23-05-1995



 
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