Refractory products formed by grains bound by carbon residues and metal silicon in powder form and process for the production thereof

• US 4,544,641 A
• Filed: 07/10/1984
• Issued: 10/01/1985
• Est. Priority Date: 12/08/1982
• Status: Expired due to Term

• Current Assignee: UCAR Carbon Company Incorporated
• Original Assignee: Societe Des Electrodes Et Refractaires Savoie
• Inventors: Michel, Christian, Dumas, Daniel, du Mesnildot, Bruno
• Primary Examiner(s): Dixon, Jr., William R.
• Assistant Examiner(s): GROUP, KARL E
• Application Number:
  US06/629,547
• Time in Patent Office: 448 Days
• Field of Search: 501/88, 501/89, 501/90, 501/99, 501/100
• US Class Current: 501/87
• CPC Class Codes: C04B 35/013 containing carbon C04B35/103 takes precedence
• CPC Class Codes: C04B 35/101 Refractories from grain sized mixtures
• CPC Class Codes: C04B 35/573 obtained by reaction sintering or recrystallisation
• CPC Class Codes: C21B 7/06 Linings for furnaces
• CPC Class Codes: C25C 3/08 Cell construction, e.g. bottoms, walls, cathodes
• CPC Class Codes: Y02P 10/134 by avoiding CO2, e.g. using hydrogen
• CPC Class Codes: Y02P 10/20 Recycling

Abstract

The invention concerns a fired refractory product based on refractory grains and binder, and process for the production thereof.

The refractory product comprises a charge of refractory grains belonging to the group comprising carbonaceous products such as anthracite, natural graphite, artificial graphite, amorphous carbon, coke, refractory compounds known as RHM such as silicon carbide and refractory oxides such as alumina, corundum, magnesia, silica and chromium oxide, taken separately, in mixture or in combination; said grains are secured together by a cement based on a coked carbonaceous product and metal silicon in powder form; and the final proportion of metal silicon is from 1 to 15.8% and preferably from 3 to 10.5%.

The product is intended for the manufacture of side linings for tanks for the production of aluminum by igneous electrolysis, and linings for blast furnaces and electric furnaces for electrometallurgy operations.

Claims

1. A fired refractory product based on refractory grains and binder consisting essentially of:

a charge of refractory grains selected from the group consisting of carbonaceous products refractory hard metal compounds, refractory oxides and mixtures thereof, and

securing together said grains, a cement based on coked carbonaceous product and metal silicon in powder form, the proportion of metal silicon being from 1 to 15.8% by weight.

2. A refractory product according to claim 1 wherein the charge of refractory grains consist essentially of grains of carbonaceous product.

3. A refractory product according to claim 1 wherein the charge of refractory grains comprises from 10 to 20% by weight of grains of refractory hard metal compound and from 90 to 80% by weight of grains of carbonaceous product.

4. A refractory product according to claim 1 wherein the charge of refractory grains comprises from 45 to 100% by weight of grains of refractory hard metal compounds and from 55 to 0% by weight of carbonaceous grains.

5. A mixed refractory block having at least two portions characterised in that a portion, is formed by a first refractory product, the other portion, for example the other face, being formed by a second refractory product, at least one of said two refractory products being of a composition according to claim 1.

6. A mixed refractory block according to claim 5 further comprising at least one intermediate layer of a third refractory product, one of the physical properties of which, is of a value intermediate between the same physical property of the first and second refractory products.

7. A process for the production of a refractory product according to claim 1, based on refractory grains and binder, comprising the steps of preparing an initial mixture consisting essentially of:

charge of refractory grains--70 to 95% by weight

pitch, tar, thermosetting resin or cokable organic binder--4 to 20% by weight

metal silicon in powder form--1 to 15% by weight

the refractory grains selected from the group consisting of carbonaceous products, refractory hard metal compounds, refractory oxides and mixtures thereof, shaping said mixture by applying a pressure and firing said shaped mixture at from 950°

to 1150°

C.

8. A production process according to claim 7 wherein the initial mixture comprises:

charge of refractory grains--75 to 90% by weight

pitch, tar, thermosetting resin or cokable organic binder--6 to 14% by weight

metal silicon in powder form--3 to 10% by weight.

9. A refractory product according to claim 1, wherein said carbonaceous products are selected from the group consisting of anthracite, natural graphite, artificial graphite, amorphous carbon, coke and mixtures thereof.

10. A refractory product according to claim 1, wherein said refractory oxides are selected from the group consisting of alumina, corundum, magnesia, silica, chromium oxide and mixtures thereof.

11. A refractory product according to claim 1, wherein the proportion of metal silicon is from 3 to 10.5% by weight.

12. A refractory product according to claim 1, wherein the charge of refractory grains comprises from 10 to 20% by weight of said grains of refractory hard metal compounds and said grains of refractory oxide, and from 90 to 80% by weight of said grains of carbonaceous product.

13. A refractory product according to claim 1, wherein the charge of refractory grains comprises from 10 to 20% by weight of said grains of refractory hard metal compounds and from 90 to 80% by weight of said grains of carbonaceous product, and said grains of refractory oxide.

14. A mixed refractory block according to claim 5, wherein said portion comprises a face of said block and said other portion comprises another face of said block.

15. A mixed refractory block according to claim 6, wherein said one of the physical properties is the coefficient of expansion.

16. A process according to claim 7, wherein said carbonaceous products are selected from the group consisting of anthracite, natural graphite, artificial graphite, amorphous carbon, coke and mixtures thereof.

17. A process according to claim 7, wherein said refractory oxides are selected from the group consisting of alumina, corundum, magnesia, silica, chromium oxide and mixtures thereof.

18. A process according to claim 7, wherein said step of firing is performed at a temperature of 1000°

to 1090°

C.

19. A side lining for a tank for the production of aluminum by igneous electrolysis comprising a refractory product according to claim 1.

20. A lining for a blast furnace or an electric furnace for electrometallurgy operations, comprising a refractory product according to claim 1.