Patents Represented by Attorney Malcolm McQuarrie
  • Patent number: 4244744
    Abstract: A refractory gun mix of improved properties, particularly low rebound, wide water range, and good adherence when gunned onto hot surfaces, used a bonding system of from 1 to 5% sodium silicate, 0.3 to 3% gypsum, and 0 to 5% bentonite, the percentages being based on the total weight of the composition. The gun mix may contain other materials, for example pulverized pitch.
    Type: Grant
    Filed: August 6, 1979
    Date of Patent: January 13, 1981
    Assignee: Kaiser Aluminum & Chemical Corporation
    Inventor: Nicholas Cassens, Jr.
  • Patent number: 4233078
    Abstract: Sodium borate, preferably a hydrated sodium borate and most preferably borax (the decahydrate), is added to a graphitic refractory composition suitable for forming a refractory monolith, for example a plastic or a ramming mix, in order to reduce the loss of plasticity of the mix during storage, to inhibit fungi formation in the mix during storage, and to improve the intermediate temperature strength of the composition.
    Type: Grant
    Filed: July 3, 1979
    Date of Patent: November 11, 1980
    Assignee: Kaiser Aluminum & Chemical Corporation
    Inventor: William E. Brown
  • Patent number: 4230652
    Abstract: Repair of furnace structures, particularly hot furnace structures, can be achieved by gunning with less dusting and rebound and higher cohesiveness, adherence, and strength in the gunned refractory when the refractory comprises an admixture of aluminosilica aggregate, plastic clay, graphite and, as binder, a liquid sodium silicate solution.
    Type: Grant
    Filed: October 20, 1978
    Date of Patent: October 28, 1980
    Assignee: Kaiser Aluminum & Chemical Corporation
    Inventors: Jim E. Allen, Robert E. Farris
  • Patent number: 4229423
    Abstract: A magnesium hydroxide of low lime and boron content is produced from a brine containing magnesium chloride and over 1 ppm boron (on a B.sub.2 O.sub.3 basis) by treating it to reduce its CO.sub.2 content to less than 15 ppm and reacting it with an excess of active lime in a first reaction stage, decanting the spent brine from the precipitated high lime magnesium hydroxide, and then reacting the high lime magnesium hydroxide with additional brine in a second reaction stage to produce a magnesium hydroxide containing less than 1% CaO and less than 0.1% B.sub.2 O.sub.3 on the ignited basis. A portion of the high lime magnesium hydroxide from the first reaction stage is recycled to that stage as seed. Before being discarded, the spent brine from the first reaction stage may be reacted with treated brine to precipitate magnesium hydroxide of relatively high CaO and B.sub.2 O.sub.3 content.
    Type: Grant
    Filed: February 9, 1979
    Date of Patent: October 21, 1980
    Assignee: Kaiser Aluminum & Chemical Corporation
    Inventors: Lloyd M. Housh, William R. Alder
  • Patent number: 4218256
    Abstract: Upper and lower plates, as well as other parts, for a slide gate valve are formed by casting into a mold, preferably a metal mold, a castable refractory composition containing from 1 to 5% of a long chain glassy polyphosphate, preferably one having an average chain length of about 20 phosphorous atoms, from 0.1 to 0.5% boric acid, the balance of the castable being sized periclase refractory grain.
    Type: Grant
    Filed: March 6, 1979
    Date of Patent: August 19, 1980
    Assignee: Kaiser Aluminum & Chemical Corporation
    Inventor: Ralph B. Videtto
  • Patent number: 4210617
    Abstract: Method of casting an integral slide gate and nozzle assembly wherein a casing (11) conforming to the exterior sides and bottom of the valve is placed upside down on a flat smooth plate (12), a tube (14) is placed within the mold so formed to produce a channel in the cast valve, a first castable refractory exhibiting good resistance to molten metal is cast in the bottom of the mold, a tube (19) is placed about the passage-forming tube (14), the same first refractory castable is cast between the two tubes, and a refractory of lesser resistance to molten metal is cast within the remainder of the mold, the second tube (19) being removed after the casting is complete. Preferably casting is carried out while vibration is applied to the mold, the vibration continuing until after removal of the second tube (19). The second refractory can be an insulating material. Preferably the first castable is a high alumina material, for example one containing over 70%, most preferably over 90%, Al.sub.2 O.sub.3.
    Type: Grant
    Filed: August 3, 1978
    Date of Patent: July 1, 1980
    Assignee: Kaiser Aluminum & Chemical Corporation
    Inventor: Jan Bowman
  • Patent number: 4166748
    Abstract: A plastic chrome ore is made from an admixture of sized chrome ore, sodium silicate, hectorite, and sufficient water to form a plastic mass. It may contain a plasticizer such as plastic kaolin clay in addition to the hectorite.
    Type: Grant
    Filed: April 27, 1978
    Date of Patent: September 4, 1979
    Assignee: Kaiser Aluminum & Chemical Corporation
    Inventor: Nicholas Cassens, Jr.
  • Patent number: 4158685
    Abstract: A foamed insulating refractory shape is made by: (1) preparing a slip of water, deflocculating agent, refractory aggregate, at least 7.5% by weight cement, and, optionally, clay; (2) forming a foam of water, foaming agent, and air having a density not over about 5 lbs per cubic foot (80 g/l); (3) admixing the slip and the foam to form a foamed slurry with a viscosity between 1000 and 30,000 centipoises, the amount of water in the slip being adjusted to yield the desired viscosity in the foamed slurry; (4) pouring the foamed slurry into molds; (5) curing the pieces so formed at a temperature not over about 72.degree. F. (about 22.degree. C.) for about 16 to 24 hours; (6) drying the pieces at a temperature not over about 200.degree. F. (about 93.degree. C.); and (7) firing the pieces. The method of this invention produces insulating refractory shapes with higher strength-to-weight ratios than those produced by prior art methods.
    Type: Grant
    Filed: March 16, 1978
    Date of Patent: June 19, 1979
    Assignee: Kaiser Aluminum & Chemical Corporation
    Inventor: Joseph S. Masaryk
  • Patent number: 4149897
    Abstract: A refractory composition, suitable for ramming, casting, or gunning, which can be heated rapidly without exploding is made from sized refractory aggregate bonded with from 0.1% to 3% MgSO.sub.4, from 0.1% to 2% sodium gluconate, and from 0.1 to 2% B.sub.2 O.sub.3 in the form of a soluble boron compound, boric acid being a preferred form. To inhibit explosion of the composition upon rapid heating, the sum of the per cent sodium gluconate and boric acid should be over 0.8, preferably over 0.9.
    Type: Grant
    Filed: April 17, 1978
    Date of Patent: April 17, 1979
    Assignee: Kaiser Aluminum & Chemical Corporation
    Inventor: Nicholas Cassens, Jr.
  • Patent number: 4126478
    Abstract: A high purity periclase grain having less than 8 volume % porosity, less than 2% SiO.sub.2, and a CaO:SiO.sub.2 weight ratio not over 1.0 is produced in a single fire process by mixing from 0.5 to 1.5% finely divided SiO.sub.2 with a magnesium hydroxide containing (on the ignited basis) at least 98% MgO, not over 1.5% CaO, and not over 1.0% SiO.sub.2, drying the admixture, compacting it at a pressure of at least 10 tons/in.sup.2 (1400 kg/cm.sup.2), and firing the compacts at a temperature of at least 1700.degree. C.
    Type: Grant
    Filed: October 17, 1977
    Date of Patent: November 21, 1978
    Assignee: Kaiser Aluminum & Chemical Corporation
    Inventor: Jan Bowman
  • Patent number: 4126479
    Abstract: A magnesium aluminate spinel-bonded refractory can be formed which does not exhibit undue expansion (due to the reaction of magnesia and alumina to form magnesium aluminate spinel) between the raw, compacted state and the fired, ceramically bonded state when fired to a temperature of 1400.degree. C if a very finely divided alumina with dense particles is used. More specifically, the alumina used has an average particle size of less than 5, preferably less than 2, microns, and a specific surface of less than 30 m.sup.2 /g, preferably about 5 m.sup.2 /g (i.e., the small crystallites or particles are dense and do not have a high surface area, as do finely divided active aluminas).
    Type: Grant
    Filed: September 15, 1977
    Date of Patent: November 21, 1978
    Assignee: Kaiser Aluminum & Chemical Corporation
    Inventor: Ralph B. Videtto
  • Patent number: 4045935
    Abstract: A metal cased refractory is made by first forming a refractory shape, which may be fired if desired, with at least one, and preferably two, shallow depressions in one of its faces. A U-shaped metal casing is also formed having a discontinuous slot running the length of its central portion. The U-shaped casing is then placed over the refractory shape so that the discontinuities in the slot overlie the shallow depressions. These discontinuities form contraction tabs which are pushed into the shallow depressions, drawing the side legs of the U-shaped casing snugly against the sides of the refractory shape and placing the central section of the casing in tension.
    Type: Grant
    Filed: September 15, 1976
    Date of Patent: September 6, 1977
    Assignee: Kaiser Aluminum & Chemical Corporation
    Inventor: Frank E. Morris
  • Patent number: 4001029
    Abstract: A refractory composition suitable for nozzle gunning, particularly onto hot surfaces, is made from sized refractory aggregate, bentonite, aluminum sulfate, and hydrated lime. Preferably the weight ratio of aluminum sulfate to hydrated lime is about 2.7.
    Type: Grant
    Filed: September 26, 1975
    Date of Patent: January 4, 1977
    Assignee: Kaiser Aluminum & Chemical Corporation
    Inventor: Nicholas Cassens, Jr.
  • Patent number: 3963508
    Abstract: A refractory cement is made by combining a clinker which is substantially all CaO.Al.sub.2 O.sub.3 (CA) with a roughly equal weight amount of an alumina which has been calcined to produce a carefully controlled morphology, particularly specific surface and pore size within relatively narrow ranges. Both materials are very finely divided, at least 80% passing a 325 mesh screen.
    Type: Grant
    Filed: November 18, 1974
    Date of Patent: June 15, 1976
    Assignee: Kaiser Aluminum & Chemical Corporation
    Inventor: Joseph S. Masaryk
  • Patent number: 3954488
    Abstract: A composition capable of being plastically deformed at high temperatures contains at least 98% MgO, less than 0.1% B.sub.2 O.sub.3, and, as principal subsidiary components, CaO, SiO.sub.2, and Al.sub.2 O.sub.3. Based on the total weight of the subsidiary components, there is about 65% CaO, from 25 to 33% SiO.sub.2, and from 10 to 2% Al.sub.2 O.sub.3. The composition is preferably substantially free of iron, but in any case the weight of Fe.sub.2 O.sub.3 is no more than one-tenth the weight of Al.sub.2 O.sub.3.
    Type: Grant
    Filed: March 19, 1975
    Date of Patent: May 4, 1976
    Assignee: Kaiser Aluminum & Chemical Corporation
    Inventor: Richard L. Coatney