Abstract: The invention relates to a method for producing a ceramic proppant, including a step for preparing an original charge material, involving the grinding of source materials, particularly magnesium-containing materials, and auxiliary materials, thus producing a charge material, granulating the charge material so as to produce granules of a proppant precursor, and firing the granules of proppant precursor, thus producing proppant granules, wherein the method includes a step for pre-firing the magnesium-containing material in a reducing atmosphere. The invention also relates to a ceramic proppant produced via the indicated method.

Abstract: The phosphor ceramic has pores with a pore diameter of 3.0 ?m or more and 12.0 ?m or less. In the phosphor ceramic, a pore volume percentage of pores with a pore diameter of 3.0 ?m or more and 12.0 ?m or less is 1.5% by volume or more and 9.5% by volume or less.

Abstract: The present disclosure relates to porous ceramic articles and a method of making the same. The porous ceramic articles have microstructure of sinter bonded or reaction bonded large pre-reacted particles and pore network structure exhibiting large pore necks. The method of making the porous ceramic articles involves using pre-reacted particles having one or more phases. A plastic ceramic precursor composition is also disclosed. The composition includes a mixture of at least one of dense, porous, or hollow spheroidal pre-reacted particles and a liquid vehicle.

Abstract: A zircon body for use in glass manufacturing is provided containing zircon grains and an intergranular phase present between the zircon grains. The intergranular phase may contain silicon oxide. The body may be exposed to a halide to at least partially remove at least a majority of the silicon oxide contained in the intergranular phase from the outer portion or to at least partially remove the intergranular phase along an outer portion of the component.

Abstract: A component includes a body including zircon (ZrSiO4) grains, the body having a free silica intergranular phase present between the zircon grains and distributed substantially uniformly through the body. The body comprises a content of free silica not greater than about 2 wt. % for the total weight of the body.

Abstract: A component includes a body including zircon (ZrSiO4) grains, the body having a free silica intergranular phase present between the zircon grains and distributed substantially uniformly through the body. The body comprises a content of free silica not greater than about 2 wt. % for the total weight of the body.

Abstract: A creep-resistant zircon article and a method of manufacturing the creep-resistant zircon article are described herein. In one example, the creep-resistant zircon article has the shape of a forming apparatus (e.g., isopipe) which is used in the fusion process to manufacture glass sheets.

Abstract: Refractory materials are provided which contain P2O5/R2O3 constituents, where R is Y, Sc, Er, Lu, Yb, Tm, Ho, Dy, Tb, Gd, or a combination thereof, and/or V2O5/R?2O3 constituents where R? is Y, Sc, one or more rare earth elements, or a combination thereof. In certain embodiments, the refractory materials are xenotime-type materials and/or xenotime-stabilized zircon-type materials. The refractory materials can be used in the manufacture of glass and glass-ceramics. For example, the refractory materials, especially those that contain P2O5/R2O3 constituents, can be used as forming structures (“isopipes”) in the fusion process for making flat sheets of glass such as the glass sheets used as substrates in the manufacture of flat panel displays.

Abstract: The present invention relates to a sintered product elaborated from a starting charge containing 75-99% of zircon, in mass percentage based on the oxides and having the following average weight chemical composition, in mass percentages based on the oxides 60%?ZrO2?72.8%, 27%?SiO2?36%, 0.1%?B2O3+GeO2+P2O5+Sb2O3+Nb2O5+Ta2O5+V2O5, 0.1%?ZnO+PbO+CdO, B2O3+GeO2+P2O5+Sb2O3+Nb2O5+Ta2O5+V2O5+ZnO+PbO+CdO?5%, 0%?Al2O3+TiO2+MgO+Fe2O3+NiO+MnO2+CoO+CuO?5%, other oxides: ?1.5%, for a total of 100%. Notably used in a glass furnace.

Abstract: Sintered product produced from a starting charge containing 75 to 99% zircon, and having the following average chemical composition by weight, the percentages by weight being based on the oxides: 60%<ZrO2+HfO2<75%; 27%<SiO2<34%; O<TiO2; O<Y2O3<3.5%; 0.1%<Nb2O5+Ta2O5<=5%; and other oxides: <1.5%; for a total of 100%, The sintered product may be used in a glass furnace.

Abstract: The present invention provides biocidal ceramic compositions incorporating a bioactive ionic species that is chemically bound in a substantially single-phase, crystalline, [NZP]-type structure, methods for producing the crystalline structures, and articles of manufacture incorporating the crystalline structures, and uses of the articles of manufacture. Bioactive ionic species can be, but are not limited to, Ag, Cu, Ni, Zn, Mn, Sn, Co, H, and combinations thereof.

Abstract: A creep-resistant zircon article and a method of manufacturing the creep-resistant zircon article are described herein. In one example, the creep-resistant zircon article has the shape of a forming apparatus (e.g., isopipe) which is used in the fusion process to manufacture glass sheets.

Abstract: Refractory materials are provided which contain P2O5/R2O3 constituents, where R is Y, Sc, Er, Lu, Yb, Tm, Ho, Dy, Tb, Gd, or a combination thereof, and/or V2O5/R?2O3 constituents where R? is Y, Sc, one or more rare earth elements, or a combination thereof. In certain embodiments, the refractory materials are xenotime-type materials and/or xenotime-stabilized zircon-type materials. The refractory materials can be used in the manufacture of glass and glass-ceramics. For example, the refractory materials, especially those that contain P2O5/R2O3 constituents, can be used as forming structures (“isopipes”) in the fusion process for making flat sheets of glass such as the glass sheets used as substrates in the manufacture of flat panel displays.

Abstract: A composition is disclosed comprising a fine zircon component having a median particle size of less than 5 ?m, a medium zircon component having a median particle size of from 5 ?m to 15 ?m, and a sintering aid, wherein the composition, after firing, has a strain rate of less than about 1×10?6/hr. A method for making a green body comprising contacting a fine zircon component having a median particle size of less than 5 ?m, a medium zircon component having a median particle size of from 5 ?m to 15 ?m, and a sintering aid, and then forming the mixture into a desired shape is disclosed.

Abstract: A zircon composition having a multi-modal particle size distribution is disclosed. The multi-modal zircon composition comprises greater than about 40 parts by weight of a coarse zircon component having a median particle size of from greater than about 3 ?m to about 25 ?m, and less than about 60 parts by weight of a fine zircon component having a median particle size of 3 ?m or less. Methods for manufacturing a green body and a fired refractory ceramic body comprising the multi-modal zircon composition are also disclosed.

Abstract: The inventive sintered product is produced from an initial feedstock having a zirconium content ranging from 75 to 99% and the following average chemical weight composition, in percentage by weight, based on oxides: 60%=ZrO2+HfO2=75%, 27%=SiO2=34%, 0.2=TiO2=1.5 %, 0.3<Y2O3=3.5 %, other oxides: =1%, to give a total of 100%. Said product can be used for glassworks.

Abstract: A composition is disclosed comprising a fine zircon component having a median particle size of less than 5 ?m, a medium zircon component having a median particle size of from 5 ?m to 15 ?m, and a sintering aid, wherein the composition, after firing, has a strain rate of less than about 1×10?6 /hr. A method for making a green body comprising contacting a fine zircon component having a median particle size of less than 5 ?m, a medium zircon component having a median particle size of from 5 ?m to 15 ?m, and a sintering aid, and then forming the mixture into a desired shape is disclosed.

Abstract: A method of sintering large refractory ceramic articles is disclosed. The method includes supporting a green refractory body on a plurality of support plates, the support plates in turn being supported by a plurality of support members having arcuate upper and lower surfaces. A setter material is disposed between the green refractory body to be sintered and the support plates. As the refractory body is sintered, the density of the article increases. Concurrently, the dimensions of the body decrease, which shrinkage, unless otherwise accommodated, may cause fracture of the body. The support plates and the structure of the support members, move to prevent the development of detrimental stresses in the refractory body as it sinters.

Abstract: A method for manufacturing a refractory ceramic body is disclosed. The method comprises contacting a zirconia precursor, a silica precursor, a sol-gel forming agent, and a preformed zircon. The method can further comprise forming the composition into a desired shape and firing the desired shape to form a dense, creep resistant refractory body. An article made by the methods above is disclosed, wherein a fine particle zircon is formed within and/or between grains of a preformed zircon.

Abstract: A composition is disclosed comprising a fine zircon component having a median particle size of less than 5 ?m, a medium zircon component having a median particle size of from 5 ?m to 15 ?m, and a sintering aid, wherein the composition, after firing, has a strain rate of less than about 1×10?6/hr. A method for making a green body comprising contacting a fine zircon component having a median particle size of less than 5 ?m, a medium zircon component having a median particle size of from 5 ?m to 15 ?m, and a sintering aid, and then forming the mixture into a desired shape is disclosed.

Abstract: A composition is disclosed comprising a fine zircon component having a median particle size of less than 5 ?m, a medium zircon component having a median particle size of from 5 ?m to 15 ?m, and a sintering aid, wherein the composition, after firing, has a strain rate of less than about 1×10?6/hr. A method for making a green body comprising contacting a fine zircon component having a median particle size of less than 5 ?m, a medium zircon component having a median particle size of from 5 ?m to 15 ?m, and a sintering aid, and then forming the mixture into a desired shape is disclosed.

Abstract: Isopipes for use in making sheet glass by a fusion process are provided which exhibit reduced sag. The isopipes are composed of a zircon refractory which has a mean creep rate (MCR) at 1180° C. and 250 psi and a 95 percent confidence band (CB) for said mean creep rate such that the CB to MCR ratio is less than 0.5, the MCR and the CB both being determined using a power law model. The zircon refractory can contain titania (TiO2) at a concentration greater than 0.2 wt % and less than 0.4 wt %. A concentration of titania in this range causes the zircon refractory to exhibit a lower mean creep rate than zircon refractories previously used to make isopipes. In addition, the variation in mean creep rate is also reduced which reduces the chances that the zircon refractory of a particular isopipe will have an abnormally high creep rate and thus exhibit unacceptable sag prematurely.

Abstract: Isopipes for use in making sheet glass by a fusion process are provided which exhibit reduced sag. The isopipes are composed of a zircon refractory which has a mean creep rate (MCR) at 1180° C. and 250 psi and a 95 percent confidence band (CB) for said mean creep rate such that the CB to MCR ratio is less than 0.5, the MCR and the CB both being determined using a power law model. The zircon refractory can contain titania (TiO2) at a concentration greater than 0.2 wt. % and less than 0.4 wt. %. A concentration of titania in this range causes the zircon refractory to exhibit a lower mean creep rate than zircon refractories previously used to make isopipes. In addition, the variation in mean creep rate is also reduced which reduces the chances that the zircon refractory of a particular isopipe will have an abnormally high creep rate and thus exhibit unacceptable sag prematurely.

Abstract: Refractory materials are provided which contain P2O5/R2O3 constituents, where R is Y, Sc, Er, Lu, Yb, Tm, Ho, Dy, Tb, Gd, or a combination thereof, and/or V2O5/R?2O3 constituents where R? is Y, Sc, one or more rare earth elements, or a combination thereof. In certain embodiments, the refractory materials are xenotime-type materials and/or xenotime-stabilized zircon-type materials. The refractory materials can be used in the manufacture of glass and glass-ceramics. For example, the refractory materials, especially those that contain P2O5/R2O3 constituents, can be used as forming structures (“isopipes”) in the fusion process for making flat sheets of glass such as the glass sheets used as substrates in the manufacture of flat panel displays.

Abstract: The invention relates to a refractory ceramic product which comprises: a) ?93% by weight of at least one refractory basic component and b) ?7% by weight of at least one anticorrosive component from the group including: b1) transition metals, b2) compounds of transition metals with each other, b3) non-oxidic compounds of transition metals, b4) oxidic compounds of transition metals, b5) compounds of the transition metals with Ca, Ba, Sr.

Abstract: A zircon composition having a multi-modal particle size distribution is disclosed. The multi-modal zircon composition comprises greater than about 40 parts by weight of a coarse zircon component having a median particle size of from greater than about 3 ?m to about 25 ?m, and less than about 60 parts by weight of a fine zircon component having a median particle size of 3 ?m or less. Methods for manufacturing a green body and a fired refractory ceramic body comprising the multi-modal zircon composition are also disclosed.

Abstract: Isopipes for use in making sheet glass by a fusion process are provided which exhibit reduced sag. The isopipes are composed of a zircon refractory which has a mean creep rate (MCR) at 1180° C. and 250 psi and a 95 percent confidence band (CB) for said mean creep rate such that the CB to MCR ratio is less than 0.5, the MCR and the CB both being determined using a power law model. The zircon refractory can contain titania (TiO2) at a concentration greater than 0.2 wt. % and less than 0.4 wt. %. A concentration of titania in this range causes the zircon refractory to exhibit a lower mean creep rate than zircon refractories previously used to make isopipes. In addition, the variation in mean creep rate is also reduced which reduces the chances that the zircon refractory of a particular isopipe will have an abnormally high creep rate and thus exhibit unacceptable sag prematurely.

Abstract: Isopipes for use in making sheet glass by a fusion process are provided which exhibit reduced sag. The isopipes are composed of a zircon refractory which has a mean creep rate (MCR) at 1180° C. and 250 psi and a 95 percent confidence band (CB) for said mean creep rate such that the CB to MCR ratio is less than 0.5, the MCR and the CB both being determined using a power law model. The zircon refractory can contain titania (TiO2) at a concentration greater than 0.2 wt. % and less than 0.4 wt. %. A concentration of titania in this range causes the zircon refractory to exhibit a lower mean creep rate than zircon refractories previously used to make isopipes. In addition, the variation in mean creep rate is also reduced which reduces the chances that the zircon refractory of a particular isopipe will have an abnormally high creep rate and thus exhibit unacceptable sag prematurely.

Abstract: Isopipes for use in making sheet glass by a fusion process are provided which exhibit reduced sag. The isopipes are composed of a zircon refractory which has a mean creep rate (MCR) at 1180° C. and 250 psi and a 95 percent confidence band (CB) for said mean creep rate such that the CB to MCR ratio is less than 0.5, the MCR and the CB both being determined using a power law model. The zircon refractory can contain titania (TiO2) at a concentration greater than 0.2 wt. % and less than 0.4 wt. %. A concentration of titania in this range causes the zircon refractory to exhibit a lower mean creep rate than zircon refractories previously used to make isopipes. In addition, the variation in mean creep rate is also reduced which reduces the chances that the zircon refractory of a particular isopipe will have an abnormally high creep rate and thus exhibit unacceptable sag prematurely.

Abstract: A glass manufacturing system is described herein that has a forming device (e.g., isopipe) which is made from a zircon refractory material that has an improved creep resistance property. The zircon refractory material has a composition with at least the following elements: ZrSiO4 (98.75–99.68 wt %); ZrO2 (0.01–0.15 wt %); TiO2 (0.23–0.50 wt %); and Fe2O3 (0.08–0.60 wt %).

Abstract: This invention concerns a non-basic refractory batch as well as its use.

Abstract: A glass manufacturing system is described herein that has a forming device (e.g., isopipe) which is made from a zircon refractory material that has an improved creep resistance property. The zircon refractory material has a composition with at least the following elements: ZrSiO4 (98.75–99.68 wt %); ZrO2 (0.01–0.15 wt %); TiO2 (0.23–0.50 wt %); and Fe2O3 (0.08–0.60 wt %).

Abstract: Isopipes for use in making sheet glass by a fusion process are provided which exhibit reduced sag. The isopipes are composed of a zircon refractory which has a mean creep rate (MCR) at 1180° C. and 250 psi and a 95 percent confidence band (CB) for said mean creep rate such that the CB to MCR ratio is less than 0.5, the MCR and the CB both being determined using a power law model. The zircon refractory can contain titania (TiO2) at a concentration greater than 0.2 wt. % and less than 0.4 wt. %. A concentration of titania in this range causes the zircon refractory to exhibit a lower mean creep rate than zircon refractories previously used to make isopipes. In addition, the variation in mean creep rate is also reduced which reduces the chances that the zircon refractory of a particular isopipe will have an abnormally high creep rate and thus exhibit unacceptable sag prematurely.

Abstract: The present invention relates to a sole-covering agent for use in a carbonization chamber of a coke oven wherein the agent includes a refractory material having an average particle diameter of 10 &mgr;m or less and a melting point higher than a wall surface temperature of a carbonization chamber during operation and an organic binder and the agent has an average particle diameter in the range of from 0.3 to 10 mm, and a method of manufacturing the same. Furthermore, a method of applying the sole-covering agent to a coke oven is also provided. According to the invention, a load generated after coating of a high temperature refractory material for use in a carbonization chamber of an oven wall and applied on a coke pushing machine can be reduced.

Abstract: Refractory coatings comprising unstabilized zirconia, silica, and, optionally, zircon and/or mullite are disclosed herein. The unstabilized zirconia, silica, and optional zircon and/or mullite are applied as a slurry onto ceramic substrates such as silicon carbide and fired. The refractory coatings of the present invention maintained good edge definition and color when applied to ceramic substrates and subjected to temperatures over 1100° C.

Abstract: Refractory coatings comprising unstabilized zirconia, silica, and, optionally, zircon and/or mullite are disclosed herein. The unstabilized zirconia, silica, and optional zircon and/or mullite are applied as a slurry onto ceramic substrates such as silicon carbide and fired. The refractory coatings of the present invention maintained good edge definition and color when applied to ceramic substrates and subjected to temperatures over 1100° C.

Abstract: Refractory coatings comprising unstabilized zirconia, silica, and, optionally, zircon and/or mullite are disclosed herein. The unstabilized zirconia, silica, and optional zircon and/or mullite are applied as a slurry onto ceramic substrates such as silicon carbide and fired. The refractory coatings of the present invention maintained good edge definition and color when applied to ceramic substrates and subjected to temperatures over 1100° C.

Abstract: A ceramic including a first phase having a general formula R1+(x/2)Zr4P6-xSixO24 where R is selected from the group consisting of Ba, Ca, and Sr and 0≦x≦2, wherein the first phase has a volumetric heat capacity (Cp1), and at least 10 weight percent of a second phase having a volumetric heat capacity (Cp2), wherein Cp2>Cp1. The ceramic has a coefficient of thermal expansion from 22° to 1000° C. of −15×10−7/° C. to +15×10−7/° C., a permeability of at least 0.25×10−12 m2, a total porosity of at least 35% by volume, and a median pore diameter of at least 6 micrometers, and a volumetric heat capacity of the solid Cp(solid) of at least 3.15 J/cm3 K.

Abstract: Transparent solid, fused microspheres are provided. In one embodiment, the microspheres contain alumina, zirconia, and silica in a total content of at least about 70% by weight, based on the total weight of the solid, fused microspheres, wherein the total content of alumina and zirconia is greater than the content of silica, and further wherein the microspheres have an index of refraction of at least about 1.6 and are useful as lens elements.

Abstract: A dry refractory composition having superior insulating value. The dry refractory composition also may have excellent resistance to molten metals and slags. The composition includes filler lightweight material, which may be selected from perlite, vermiculite, expanded shale, expanded fireclay, expanded alumina silica hollow spheres, bubble alumina, sintered porous alumina, alumina spinel insulating aggregate, calcium alumina insulating aggregate, expanded mulllite, cordierite, and anorthite, and matrix material, which may be selected from calcined alumina, fused alumina, sintered magnesia, fused magnesia, silica fume, fused silica, silicon carbide, boron carbide, titanium diboride, zirconium boride, boron nitride, aluminum nitride, silicon nitride, Sialon, titanium oxide, barium sulfate, zircon, a sillimanite group mineral, pyrophyllite, fireclay, carbon, and calcium fluoride.

Abstract: A cementitious matrix consisting essentially of aluminosilicate polymer containing a liquid component of an aqueous solution of an alkali metal silicate having the formula M2O.RSiO2.XH2O, in which: M is an alkali metal monovalent cation such K+ or Na+; R is the molar ratio of SiO2/M2O, where the range is between 0.5/1 and 9/1; and X is the amount of water, where the amount of water is between 30 and 70 wt %; and a powder component which contains the silico-aluminous reactive raw materials Al6Si2O13 and Al2O3.4SiO2, with a relative proportion between 40 and 60 wt %, where the particle size of both components ranges between 40 and 70 microns. The cementitious matrix has high mechanical strength and is resistant to high temperatures.

Abstract: A ceramic including a first phase having a general formula R1+(x/2)Zr4P6−xSixO24 where R is selected from the group consisting of Ba, Ca, and Sr and 0≦x≦2, wherein the first phase has a volumetric heat capacity (Cp1), and at least 10 weight percent of a second phase having a volumetric heat capacity (Cp2), wherein Cp2>Cp1. The ceramic has a coefficient of thermal expansion from 22° to 1000° C. of −15×10−7/° C. to +15×10−7/° C., a permeability of at least 0.25×10−12 m2, a total porosity of at least 35% by volume, and a median pore diameter of at least 6 micrometers, and a volumetric heat capacity of the solid Cp(solid) of at least 3.15 J/cm3 K.

Abstract: Transition metal NZP type compounds are synthesized. Examples of these compounds include MnZr4(PO4)6, FeZr4(PO4)6, CoZr4(PO4)6, NiZr4(PO4)6, and CuZr4(PO4)6. These compounds are synthesized by the Xerogel process. These transition metal NZP type compounds can be used as colorants in applications such as ceramic glazes where high thermal stability of the colorant is important.

Abstract: A foundry exothermic assembly is formed by mixing hollow glass microspheres and an inorganic or organic binder with matrix forming constituents including an oxidizable metal, an oxidizing agent, a foundry refractory aggregate and, optionally, a pro-oxidant, and shaping and curing the mixture. The hollow glass microspheres are dispersed and embedded in the assembly matrix.

Abstract: An article of relatively pure silica, and a furnace and method of producing the article. The article is produced by collecting molten silica particles (24) in a refractory furnace in which at least a portion of the refractory has been exposed to a halogen-containing gas to react with contaminating metal ions in the refractory.

Abstract: The invention relates to a novel sintered material, characterized in that it is produced from a batch containing 5 to 40% zircon and in that it has the following chemical composition in % by weight:______________________________________ ZrO.sub.2 + HfO.sub.2 82-96 SiO.sub.2 1.7-14 TiO.sub.2 0.2-3 Y.sub.2 O.sub.3 0.4-5 Al.sub.2 O.sub.3 0.2-2.

Abstract: A shaped ceramic article capable of being cut manually into selected sizes and process is based on a mixture of high-temperature resistant ceramic fibers and fibers which soften at temperatures below 2000.degree. F., particles of a ceramic material stable to temperatures exceeding 2000.degree. F., particles of a ceramic material which sinter at temperatures below 2000.degree. F., and a binder which provides green strength to shapes formed by vacuum formation from a slurry. The vacuum formed shape is dried at about 400.degree. F., thereby dried to form a shape which is preferably dipped in colloidal alumina or silica and dried again. The shape is sinterable by contact with flowing molten metal or by being sujected to radiant heat to form a hardened shape-stable ceramic form.

Abstract: A reaction-formed moulded ceramic body containing mullite is described which is obtainable by heat treating a body moulded from a finely dispersed powder mixture of aluminium, Al.sub.2 O.sub.3 and a material containing Si in an atmosphere containing oxygen. Due to their properties, in particular their low shrinkage of 0 to 4% on average, the moulded bodies are very well suited for use as wear-resistant and/or high temperature-resistant components in the construction of machines, apparatuses and motors, as a cutting tool, as a component for bearings and/or seals and as a functional part in electronic instruments.

Abstract: Plasticized inorganic powder batches comprising a cellulosic binder, water, and at least one inorganic powder exhibiting relatively high water affinity are compounded by combining the inorganic powder, prior to any contact with the water or cellulosic binder, with an organic surface treatment agent to decrease the water affinity thereof; subsequent mixing of the treated powder with the water and the cellulosic binder forms a plasticized inorganic powder batch with improved extrusion, molding, or other shaping characteristics.

Abstract: The present invention is a sintered ceramic article having an elemental composition including Zr, O, and at least one element selected from the group consisting of Mg, Ca, Y, Sc, Ce and rare earth elements. The ceramic article includes a core and a casing. The casing is exterior to and continuous with the core. The core is a mass of sintered particles having an essentially tetragonal zirconia crystalline structure and the casing is a mass of sintered particles having a mixture of monoclinic zirconia crystalline structure and zircon crystalline structure.