Abstract: Gunning apparatus adapted to be carried by a mobile device such as a fork lift truck and inserted in a side door of a furnace such as an electric furnace and used to gun refractory material onto the inside surface of the furnace lining comprises a boom with one end adapted to be attached to the mobile device and the other end carrying a spray nozzle which can be rotated about a vertical axis, the boom also carrying channels to convey, separately, refractory and water to a mixer where the refractory and water are admixed, a channel to carry the admixture to the spray nozzle, and a motor to rotate the spray nozzle.

Abstract: For improving permeability of a metallurgical vessel bottom provided with permeable refractory elements for controlled injection of a stirring fluid into a molten metal bath, the metallurgical vessel is emptied of its contents, a castable composed of a refractory material compatible with the refractory material of the bottom is deposited in the bottom and spread over the latter, and the castable is left to dry and set, while maintaining in the permeable refractory elements a sufficient pressure to provide a permanent flow of a stirring fluid. A hydraulic magnesian refractory castable used in this method has a content of water of substantially between 8 and 10% by weight.

Abstract: A foundry furnace lining is formed using an improved ramming mix composed predominantly of raw kyanite particles and alumina particles. The particulate mix is sintered to form a silica slag-resistant lining, which sintering is accompanied by reactions that produce compressive forces that strengthen the product lining.

Abstract: A method for torch guniting of a metallurgical unit, wherein a guniting force formed by a guniting mix, fuel and oxygen is directed into the refractory lining of the unit involved. Simultaneously the guniting torch is exposed in the effect of a wave energy field which is established by virtue of sonic vibrations which are maximally concentrated at the guniting torch.

Abstract: The present invention relates to a two-part gunning refractory composition wherein fine powders of a refractory aggregate and superfine refractory powders are previously made into the form of a slurry containing therein a deflocculant, thereby reducing the amount of aluminous cement and also reducing the amount of water to achieve a deposit applied by gunning having a quality comparable to one produced by casting.

Abstract: The service life of permeable refractory elements is improved by conserving in a vessel a fluid slag formed during refining of a charge after a liquid metal has been cast by tipping the vessel, depositing and spreading the slag over the bottom by bringing the vessel back to its upright position, and leaving the slag to harden and set on the bottom, while a sufficient pressure is maintained in the permeable refractory elements to ensure a permanent flow of a stirring fluid.

Abstract: A ladle of the type having a bottom wall, sidewall and opposite trunnions extending outwardly from an upper portion of the sidewall is provided with a refractory lining by positioning a mandrel inside of the ladle in spaced relationship to the walls thereof to define a castable space. The mandrel is attached to an elongated horizontal support which extends over the top of the ladle. The elongated horizontal support is supported by the ladle trunnions and is also locked thereto against upward displacement. At least a portion of the mandrel which cooperates with the ladle sidewall is expandable and collapsible toward and away from the ladle sidewall. After the castable space is filled with castable refractory material, such material is allowed to solidify, and the elongated horizontal support is released from the trunnions so that the support and mandrel attached thereto can be lifted upwardly.

Abstract: Apparatus and method for filling the well of a molten metal ladle or like vessel with a pre-selected charge of disposable refractory sand is disclosed. The apparatus includes a disposable can positioned above and in the blocking and at the top of the well. The can includes a plurality of apertures spaced around said can. The apparatus includes a unit hopper that is filled with a preselected charge of sand and is suspended from an overhead crane and maneuvered by crane controls from a safe distance. The hopper unit includes latches for releasably holding the can at its bottom and a trigger mechanism for discharging the sand in response to the seating of the can on a surface and the lowering of the hopper unit through the can. The operator may charge the hopper with sand, latch the can to the bottom of the apparatus, maneuver it into and over the ladle to the well and lower it so that the can is seated above the well.

Abstract: For improving permeability of a metallurgical vessel bottom provided with permeable refractory elements for controlled injection of a stirring fluid into a molten metal bath, the metallurgical vessel is emptied of its contents, a castable composed of a refractory material compatible with the refractory material of the bottom is deposited in the bottom and spread over the latter, and the castable is left to dry and set, while maintaining in the permeable refractory elements a sufficient pressure to provide a permanent flow of a stirring fluid. A hydraulic magnesian refractory castable used in this method has a content of water of substantially between 8 and 10% by weight.

Abstract: The service life of permeable refractory elements is improved by conserving in a vessel a fluid slag formed during refining of a charge after a liquid metal has been cast by tipping the vessel, depositing and spreading the slag over the bottom by bringing the vessel back to its upright position, and leaving the slag to harden and set on the bottom, while a sufficient pressure is maintained in the permeable refractory elements to ensure a permanent flow of a stirring fluid.

Abstract: A laminar block for lining an inner wall of a furnace is composed of a number of individual laminated sheets of inorganic fibers sewed together by means of chain stiches. When the laminar block is cut to size, severing the thread, the chain stitches prevent the laminated sheets from separating.

Abstract: A high temperature resistant refractory mortarless joint wall and method made from pre-formed, unburned plastic refractory blocks having siliceous clay, and from ten percent to seventy-five percent pyrophyllite, by weight, and workability from twenty percent to forty percent when erected before drying and firing.

Abstract: This invention relates to a repairing apparatus for an industrial furnace wall using a plasma spray gun. The plasma flame of the gun traces the damaged part to be repaired by moving the gun in three-dimensional directions (up-and downwardly, right-and leftwardly, and forwardly and backwardly) relative to the furnace wall to be repaired. Furthermore, the optimum spray distance of the plasma flame follows the unevenness of the furnace wall and the depression extent of a damaged part to be repaired from the sound surface of a furnace wall by changing the mixture ratio of the operation gas for the gun to control the length of the plasma flame.

Abstract: An infrared ray reflective coating for application to insulative materials comprising aluminum particles in an aqueous acidic binder slurry, a hardener, and a coating cement having about 96% of a mixture of Al.sub.2 O.sub.3 and SiO.sub.2.

Abstract: A method and apparatus for improved preheating and/or curing of the channel of an induction furnace wherein an elongated burner tube is provided with a combustion zone adjacent its forwardmost end and an air inlet is provided adjacent its opposite end outside of the furnace to provide high velocity and high volume air flow to cool the burner tube extending within the furnace and support combustion within the burner combustion zone.

Abstract: The installation comprises a shaping mould 1, 2 adapted to the geometry of the container C and made from a plurality of elements so as to permit a free expansion of the mould in the course of use, arrangements 3, 4, 5 for supporting and handling the mould 2, 3, devices 6, 14 for centering and fixing the mould relative to the container C so as to define between the inner wall of the container C and the mould a space for receiving refractory concrete, and devices 7, 8, 11 for supplying refractory concrete to this space.

Abstract: Molten pig iron flows from the hearth of a blast furnace down a runner positioned on the floor of a cast house and into ladles for receiving the iron. The runner is constructed by a plurality of precast refractory side blocks and an interconnecting base of compacted particulate refractory material to form a substantially U-shaped trough extending a preselected distance and along a preselected path from the hearth to one or more ladles for conveying the iron from the blast furnace. The trough has opposed upstanding side walls and a floor extending between the bottom of the side walls. The side walls are formed by individual side blocks positioned in abutting end to end relation on the cast house floor. The compacted base forming the trough floor extends between and interconnects with the side blocks. The adjacent ends of the side blocks are notched to form a joint for receiving castable refractory material which upon setting interlocks the ends of adjacent side blocks.

Abstract: Plastic composition which can be processed into a fire-resistant material, use thereof, and process for its production, which process comprises mixing ceramic fibers with a substantially dry organic bonding agent to produce a first mixture, mixing the first mixture with water to produce a second mixture, mixing the second mixture with clay to produce a third mixture, and mixing the third mixture with an aqueous solution of an organic bonding agent to produce a fourth mixture, with the proviso that the ceramic fibers account for at least 74% by weight of the solids content in the plastic composition.

Abstract: A refractory slide gate for a container dispensing molten material is comprised of a metal-supporting can filled with a low-fired coherent bonded refractory. The refractory is formed into a coherent refractory body within the metal supporting can and is directly affixed thereto, without the use of refractory mortar. An orifice through the refractory controls the flow of molten material.

Abstract: A silica refractory structure may be added to, e.g. by way of repair, in a working environment at a temperature in excess of 600.degree. C. Such addition is made using one or more vitreous silica bricks bonded into position by projecting a mixture composed of finely divided particles of exothermically oxidizable material, e.g. Si optionally with Al and particles of silica, and burning the mixture during its projection to form a coherent refractory mass which bonds the addition together and to the original structure.

Abstract: A method for the gunning of refractories characterized in that a refractory mixture consisting of a refractory aggregate and a binder is mixed in a nozzle with water, and thereafter the admixture is injected toward the working surface, while said nozzle is slidable and rotatable in the range from the vertical to 45.degree. at the angle to the working surface and further it is turnable by 360.degree. to the axis passing its fulcrum.

Abstract: A holding furnace for molten metal comprises an inner vessel formed of flat, rigid, heat-resistant panels. The panels are held in sealing engagement with one another at abutting edge surfaces by the action of inwardly directed pressure applied to the panels by an integrally cast refractory outer vessel through the intermediary of a resilient layer of heat-resistant fibrous material. The pressure is applied as a result of the shrinking that the casting compound undergoes during the setting. When the inner vessel is being made, the panels, to which the resilient layer has initially been applied, are held together by the action of a reduced pressure in the inner vessel as the latter is positioned in a furnace casing interiorly lined with a mineral wool insulation. The inner vessel then is cast around with a refractory casting compound for forming the outer vessel.

Abstract: A method of manufacturing a composite refractory article having a flow passage through which a molten metal stream may be conducted and comprising a first body of refractory material which defines a surface of that passage, the first body being bonded to a second body of refractory material. The second body is provided to define a passageway of greater cross-sectional dimensions than the flow passage. Within the passageway, the first body of refractory material is provided for defining the flow passage surface, the first body being formed in the larger passageway by causing its refractory material to cohere and bond to the second body by fusion or partial fusion in situ.

Abstract: In a process of forming a refractory mass in which having an average grain size of less than 50 .mu.m are burned while mixed with solid particles of at least one incombustible refractory material during projection of the mixture against a surface to form a coherent mass on said surface, the oxidizable material comprises silicon and aluminium, the aluminium being present in an amount not exceeding 12% by weight of the total mixture.

Abstract: A method for flame spraying of gunite on the lining of metallurgical units, comprising a delivery of a mixture of a refractory material and fuel in a central axisymmetric flow and a delivery of oxygen in an annular flow concentric with the flow of the refractory material and fuel, a heating and fusion of the refractory material in a high-temperature flame, and applying particles of the refractory material to the surface of the lining. Oxygen is delivered in a tapering annular flow rotating about its axis. The ratio between the rotation momentum of the oxygen flow and the momentum of the flow of the refractory and fuel is maintained in the range of 0.3 to 3.0.

Abstract: Molten pig iron flows from the hearth of a blast furnace down a runner positioned on the floor of a cast house and into ladles for receiving the iron. The runner is constructed by a plurality of precast refractory side blocks and an interconnecting base of compacted particulate refractory material to form a substantially U-shaped trough extending a preselected distance and along a preselected path from the hearth to one or more ladles for conveying the iron from the blast furnace. The trough has opposed upstanding side walls and a floor extending between the bottom of the side walls. The side walls are formed by individual side blocks positioned in abutting end to end relation on the cast house floor. The compacted base forming the trough floor extends between and interconnects with the side blocks. The adjacent ends of the side blocks are notched to form a joint for receiving castable refractory material which upon setting interlocks the ends of adjacent side blocks.

Abstract: A core for blow-forming the lining of a vessel for molten metal, which core is provided with a main body having blow-in holes and an exhaust port, the side face and the lower faces of said body having the same dimensions and shapes as those of the inside of the lining of said vessel for molten metal, a flange mounted approximately horizontally in the outer direction at the periphery of the upper end of said main body, a plurality of supports which are actuated downwardly from said flange, and airtight and shock absorbers mounted beneath said flange, a lining method which uses said core, and a lining composition used in said lining method.

Abstract: Method for repairing the damaged refractory lining wall of a blast furnace which includes cutting an opening through the steel shell and the refractory bricks of the furnace, inserting an injection nozzle for injecting a repair material into the opening, the injection nozzle being provided with a plurality of reinforcing studs, injecting the repair material into the furnace under pressure via the injection nozzle, and simultaneously imparting an external force onto the plurality of reinforcing studs to automatically build up a repaired refractory brick having the reinforcing studs imbedded therein.

Abstract: A high temperature refractory brick wall is repaired by removing and replacing damaged brick while the wall is maintained at a temperature below normal operating temperature but sufficiently high to avoid damage from contraction resulting from cooling. New brick having a coefficient of thermal expansion compatible with the heated wall are used to avoid cracking of the wall due to expansion during heat-up. Workers wearing protective clothing, preferably incorporating a circulating fluid cooling system, remove the damaged brick and install new brick in their place in walls having surface temperatures of about 500.degree. F. or higher and internal temperatures substantially above 500.degree. F., preferably at least about 1500.degree. F.

Abstract: The brick lining of a furnace or other high temperature enclosure is veneered by adhesively securing to the brick lining 10 blocks 11 of ceramic fiber material that have been made by a vacuum casting process and have been pre-fired prior to installation. An undercut rabbet 13 may be provided along the periphery of the cold face of the blocks to provide an additional key between the adhesive and the blocks. A jointing layer 14 of a resilient ceramic fiber felt is disposed between the side faces of adjoining blocks.

Abstract: A method of forming an insulation module for insulating the walls of a furnace, the method including forming holes at spaced intervals in a cold face of a mat of ceramic insulation material, applying a liquid adhesive to the cold face, vibrating the adhesive to cause the adhesive to penetrate into the holes of the mat, and providing a backing panel on the cold face.

Abstract: A form is provided for use in vessels having a shell and tube configuration with refractory material protecting the tube sheet to provide a flared entrance or exit for the tubes. The form has a shank end, formed as a cylinder for insertion within the tubes, and a flared end which expands at an angle of from about 15.degree. to about 20.degree..

Abstract: A two part castable ceramic cement having low density, good thermal shock resistance, good temperature resistance and extended storage life. The first and second parts are mixed together prior to use. The first part is a slurry of solids in water. The solids comprise 0 to 10 weight percent organic fibers, about 35 to about 80 weight percent ceramic organic fibers, about 5 to about 15 weight percent colloidal silica and about 3 to about 10 weight percent organic adhesive. The second part is essentially dry and comprises from about 50 to about 100 weight percent calcium aluminate.The invention further includes a method for forming the cement by mixing the two parts and includes the cast cement resulting from casting and drying the mixed first and second parts.

Abstract: Improvements in the method of applying monolithic refractory material by spraying wherein, the work surface to be lined is surrounded by a screening member such as wire nettings having suitable air escape openings, and the refractory material is sprayed within the surrounding to form a lining.Material loss due to scattering may be minimized and the work environment may be substantially improved by virtue of the screening member, and a rigid and strong refractory lining of required thickness can be obtained.

Abstract: A hollow, disposable former for use in forming a lining in a metallurgical vessel e.g. a ladle for holding molten metal comprises a plurality of connected adjacent wall portions of drywall having dimensions and configurations to provide an outer surface which corresponds to the desired inner surface of the lining to be formed.

Abstract: The invention relates to the method for hot repairing various kinds of pig iron and steel making furnaces wherein a hot repairing material made in the state of slurry by adding 10-50 weight % water to a monolithic refractory comprising refractory and/or carbon-containing granulated particles and a binder is projected onto a worn part necessitating repairs in the high temperature furnace, the water in the projected hot repairing material boiling under the high heat in the furnace whereby said repairing material is not only fully mixed but also permitted to flow into the minutest recesses of the part necessitating repairs, said repairing material being hardened with the termination of the boiling thereby enabling to form in the worn part a fabricated body having high packing, strength and corrosion resistance.

Abstract: An apparatus for building up and repairing a refractory lining of an industrial furnace by means of a rotary disc centrifugally throwing particulate refractory material against a portion of the lining to be repaired comprises a horizontal row of hollow bolts with bores to spray water into an inlet conduit of annular cross section whereby the material passing through the conduit to the disc will be uniformly wetted. Wiper elements in the conduit prevent jamming of the material therein and finely divided compressed gas is blown in the inlet funnel that supplies the material to the conduit.

Abstract: There is disclosed the distribution of an amorphous refractory in a case where a lining frame is positioned within a molten metal vessel preliminarily lined with a permanent lining refractory and the amorphous refractory is cast into the space between the permanent lining refractory and the lining frame thereby applying a lining to the inner surface of the vessel.A conical distributor is arranged above the lining frame and the amorphous refractory is continuously delivered from a rotary chute onto the distributor so as to describe a concentric path of moving falling points.

Abstract: A method of making a thermal-insulating panel for use in an electric furnace. A refractory fiber mat is formed in a felting box from a suspension of discrete refractory fibers plus an inorganic bonding agent. The modules have a hot face, a cold face and a plurality of side faces. A plurality of individual ceramic supports are partially embedded in said mat and protrude outward from the hot face. The embedded portions are shaped so as to be firmly anchored within the mat, and the protruding portions are shaped to support an electrical resistance heating ribbon in the interior of the furnace.The modules are preferably formed in a special felting box having a front wall that has a plurality of cavities from which the ceramic supports extend horizontally into the main portion of the box. The layers of fibers build up upon the bottom screen in planes perpendicular to the hot face of the module.

Abstract: The invention relates to a process for repairing hot refractory linings by applying a refractory composition by spraying on to the part of the lining to be repaired. The invention resides in the improvement comprising applying a composition containing an effective amount of combustible elongated channel-forming elements substantially evenly distributed throughout the composition.

Abstract: An apparatus and method for making a hearth of kiln under vibration comprising mounting vibrating mechanisms to a pressurizing plate in which the area of the pressurizing surface is in the range 0.5-5 m.sup.2, and said vibrating mechanisms are mounted to the pressurizing plate directly or through a frame.

Abstract: A method and apparatus is provided for repairing the worn tap hole of a steel converter to restore same to a desired diameter wherein elongated jet spray means are placed centrally into and in close proximity to the surface of the damaged tap hole and thereafter refractory mortar repair material is sprayed against the surface of the inner circumference of the worn tap hole wall to restore the diameter of same to the desired dimension.

Abstract: A taphole in a blast furnace is plugged up by charging a mud into the taphole, driving a steel rod into the mud by means of an opener, stopping the driving of the steel rod into the mud when a rear end of the steel rod positions in the middle of the furnace wall and again charging a mud into a cavity behind the rear end of the steel rod embedded in the mud.

Abstract: In repairing lining damage in a blast furnace, the furnace is blown down after lowering the burden inside to below the damaged part. Then a plurality of openings and a refractories filling aperture are provided through the furnace wall in the damaged part. A preliminarily prepared panel is lowered down through an opening in the furnace top to a position opposite to the damaged part. One end of a string-like member whose other end is fastened to the panel is drawn outside the furnace through one of the openings. The whole length of the string-like member is protectively covered by a single or double support tube and stretched therethrough. Monolithic refractories are forced in through the refractories filling aperture into a clearance between the damaged part and panel either during blowing down or after blowing in.

Abstract: A method of operating "wet bottom" practice soaking pits to prolong useful period between bed replacement. Olivine is used to replace coke breeze in the bottom of the soaking pit to protect its refractory lining.Operating periods from 40-60 days are possible when olivine is used in the soaking pit. The olivine has excellent temperature stability, also, so it is well suited for this application, in which temperatures range from about 2400.degree.-2650.degree. F.

Abstract: A spalled and deteriorated portion of a refractory brick heating wall of a coke oven heating chamber is dismantled. The deteriorated brick is removed with the undamaged brick remaining in place. Individual thermally destructable forms forming the gas flow passageways are vertically erected surrounding ports in the floor through which preheated gas and preheated air are separately supplied into the heating chamber. A second set of destructable forms having passageways forming the heating flues for receiving the products of combustion are positioned between the forms for the gas flow passageways. Horizontal forms, also forming gas flow passageways, connect adjacent vertical forms for the flow of air and gas from the ports into the heating flues where combustion of the air and gas takes place. When the thermally destructable forms are in place, a refractory material is sprayed onto the outer surfaces of the forms.

Abstract: Slag deposited on the bottom of a steel making furnace, especially a soaking pit for steel ingots, is difficult to remove. To enable this to be done while the furnace is hot, it is now proposed to supply a substance, e.g. ferro-silicon, which lowers the melting point of the slag, and a substance which reacts exothermically to initiate melting of the slag. When the slag is sufficiently liquefied, it is removed by means of a mechanical grab.

Abstract: An apparatus is disclosed for securing a two component lining to the inside shell of a rotary kiln or the like. The apparatus includes a plurality of standoffs each having a bottom portion for connection to the inside shell of the kiln, a middle portion, and a top portion. A grid is connected to each of the top portions by means of a weld. A layer of a lightweight first castable material having high insulative properties is gunned or cast along the inside shell of the kiln to a depth less than the height of the standoffs. A second castable material having abrasion resistive properties is gunned or cast onto the surface of the first castable material at a depth substantially level with the surface of the grid. The standoffs serve as an anchor to secure the two layers of castible material into position . The grid connected to the top portion of the standoffs is preferably a honeycomb grid which aids the second castable material in protecting the first castable material from damage due to abrasion.

Abstract: A method of lining an interior surface of a furnace with roll-type insulation by attaching a plurality of hooks onto the interior surface to be lined, folding back portions of the roll-type insulation on themselves to create folds in the roll-type insulation, and pressing the folds onto the hooks to thereby attach the roll-type insulation to the interior surface. Each of the plurality of hooks includes a hook member for passage through portions of the roll-type insulation. Each hook member is fixedly attached to the interior surface of the furnace either by being welded directly thereto when the interior surface of the furnace is metal or by being fixedly attached to a plate member which is in turn bolted, riveted, or otherwise fixedly attached to the interior surface of the furnace. The hook member includes a leg portion having a pointed first end for passage through the roll-type insulation and having a second end.

Abstract: The invention relates to a process for packing, also known as lining, electrometallurgical furnaces.The packing is produced from a concrete which is poured in situ or in precast blocks, composed of a setting cement having a low water retention capacity and low porosity and of an aggregate of which at least a proportion is a carbonaceous product such as anthracite. This packing has a noteworthy resistance to the constituents of fluoride-based igneous electrolysis baths and to liquid aluminum.Application to the packing of igneous electrolysis cells for the production of aluminum.