Abstract: A high-chromia refractory, comprised of: about 60% to about 99% by weight of refractory grain, wherein the refractory grain is comprised of grains having about 20% to 100% by weight chromia; 0% to about 35% by weight of a fine particulate, the fine particulate selected from chromic oxide, alumina, ceria, yttria, lanthanum oxide, or combinations thereof; and about 1% to about 8% of a liquid resin or pitch.

Abstract: A carbon baking furnace having spaced-apart, hollow flue walls defining a soaking pit therebetween. Each of the flue walls is formed of refractory bricks and has a pit face facing the pit and a flue face facing an inner flue gas passage. A coating is provided on the pit face of the flue walls. The coating increases the emissivity value of the pit face, wherein the emissivity value of the pit face is greater than the emissivity value of the flue face.

Abstract: Rotary kiln heat exchangers having precast hub and leg assemblies are disclosed. The hub and leg assemblies include interlocking features which secure the heat exchanger components together. A method of installing such heat exchangers in rotary kilns is also disclosed. Installation is relatively fast and simple, and the heat exchangers are capable of withstanding the harsh operating conditions of rotary kilns for extended periods of time.

Abstract: Rotary kiln heat exchangers having precast hub and leg assemblies are disclosed. The hub and leg assemblies include interlocking features which secure the heat exchanger components together. A method of installing such heat exchangers in rotary kilns is also disclosed. Installation is relatively fast and simple, and the heat exchangers are capable of withstanding the harsh operating conditions of rotary kilns for extended periods of time.

Abstract: An essentially non-slumping sprayable refractory castable composition that is applied without forms is disclosed comprising (a) a tempered, pumpable first component comprising (i) one hundred weight percent of a refractory composition comprising from about 60 to 90 weight percent of a refractory aggregate, from about 2 to 25 weight percent of an ultrafine refractory material having an average particle diameter size less than or equal to about 3 microns, from about 0.5 to 15 weight percent of a binder, and from about 0.05 to 2.

Abstract: An essentially non-slumping sprayable refractory castable composition that is applied without forms is disclosed comprising (a) a tempered, pumpable first component comprising (i) one hundred weight percent of a refractory composition comprising from about 60 to 90 weight percent of a refractory aggregate, from about 2 to 25 weight percent of an ultrafine refractory material having an average particle diameter size less than or equal to about 3 microns, from about 0.5 to 15 weight percent of a binder, and from about 0.05 to 2.

Abstract: A refractory castable composition is disclosed comprising one hundred weight percent of a refractory composition comprising from about 60 to 90 weight percent of a refractory aggregate, from about 2 to 25 weight percent of an ultrafine refractory material having an average particle diameter size less than or equal to about 3 microns, from about 0.5 to 15 weight percent of a binder, and from about 0.05 to 2.0 weight percent of a dispersant, wherein all or a portion of the ultrafine refractory material comprises a thermal black such that the refractory composition comprises from about 2 to 15 weight percent of the thermal black, and from about 3 to 10 weight percent water based upon 100 weight percent of the refractory composition, and wherein the water is present in an amount sufficient to achieve a castable consistency. A method of installing the refractory castable composition is also disclosed.

Abstract: A method of applying a castable refractory composition using a form. The refractory composition consists essentially of from about 50.0 weight percent to about 99.9 weight percent of a high purity silicon dioxide and from about 0.1 weight percent to about 30.0 weight percent of a potassium silicate binder. About 0.1 weight percent to about 30 weight percent water based upon 100 weight percent of the refractory composition may be added to achieve a pumpable consistency of the refractory composition.

Abstract: A refractory composition is disclosed comprising a high purity silicon dioxide and a binder. This refractory composition may be applied by trowelling, brushing, casting, pumping and/or spraying it on a worn and/or damaged high purity silica refractory surface. A refractory castable composition is also disclosed that may be employed with forms. Further, an essentially non-slumping, sprayable refractory castable composition that is applied without the use of forms is provided. The sprayable refractory castable composition comprises (a) a tempered, pumpable first component comprising (i) a high purity silicon dioxide and a binder, and (ii) water, if needed, to achieve a pumpable consistency, and (b) a second component comprising a flocculating agent. The flocculating agent is added to the first component for achieving installation of the sprayable refractory composition in an amount to prevent slumping of the sprayable refractory castable composition.

Abstract: An interconnected precast module refractory leveling assembly for a metallurgical vessel is disclosed. The precast modules of the instant invention compensate for the sloping bottom of a metallurgical vessel. At least one precast module is disposed in each of two partial rings each of which is essentially a mirror image of the other so that the height of the leveling assembly varies substantially uniformly from a high point where the two mirror image portions join to a low point 180 degrees of arc displaced therefrom where the two portions again join. Each of the refractory precast modules has a slight taper in height so that the ends of each precast module are the same height as the juxtaposed ends of the adjoining precast module.

Abstract: A metallurgical vessel having a sloping bottom surface which includes a tapered upper surface terminating at a vertical surface, wherein the vertical surface terminates at a lower tapered surface for forming a pocket block reservoir such that the pocket block reservoir has a volume of less than or equal to about five percent of the total volume of the metallurgical vessel is disclosed. This pocket block reservoir provides an area for the accumulation of residue metal and slag when the metallurgical vessel is discharged, therefore resulting in a significant increase in the quantity of usable pure metal discharged from the metallurgical vessel and thus contributing to improved volumetric efficiency of the vessel. A method for improving the yield efficiency in the production of metal employing this vessel is also provided.

Abstract: A ladle brick leveling set for high temperature molten metal ladles in which specially shaped refractory bricks are disposed in a slightly sloping geometrical configuration so as to compensate for a sloping bottom of a high temperature molten metal ladle. The bricks are disposed in two partial rings each of which is essentially a mirror image of the other so that the height of the leveling set varies substantially uniformly from a high point where the two mirror image portions join to a low point 180 degrees of arc displaced therefrom where the two portions again join. Each of the refractory bricks has a slight taper in height so that the ends of each brick are the same height as the juxtaposed ends of the adjoining bricks.

Abstract: A pulverulent fiber-reinforced spray mix is disclosed in which about 0.02 to 0.3 wt. % of flexible, thermoset polymer fibers resistant to decomposition at a temperature up to about 400.degree. F. are added for each 100 wt. % of other solids in the mix to form a mix which both avoids formation of mat-like structures in the dry hopper of refractory spray apparatus and provides a sprayed lining that is resistant to cracking and peeling during dry-out and preheat. The invention also comprises sprayable compositions formed by admixing water with the mix.

Abstract: Refractory door jamb assemblies for high temperature furnaces. The door jamb assemblies include alternating courses of refractory brick shapes, selected ones of which are fitted with apertures that are aligned as by drilling, when the bricks are installed. One or more steel rods are inserted through the aligned apertures to fasten and retain the bricks in the desired position so as to cooperatively act with the bricks and prevent them from moving when subjected to thermal and mechanical forces encountered in use.

Abstract: Mixes suitable for casting or gunning containing a heat-resistant aggregate blend containing at least about 50 wt. % high alumina grain, silicon carbide, and zircon sand, and to the method of utilizing the same to form alkali-resistant linings in high temperature vessels that have improved resistance to build-up.

Abstract: Rotary kiln heat exchangers having precast hub and leg assemblies are disclosed. The hub and leg assemblies include interlocking features which secure the heat exchanger components together. A method of installing such heat exchangers in rotary kilns is also disclosed. Installation is relatively fast and simple, and the heat exchangers are capable of withstanding the harsh operating conditions of rotary kilns for extended periods of time.

Abstract: Rotary kiln heal exchangers having precast hub and leg assemblies are disclosed. The hub and leg assemblies include interlocking features which secure the heat exchanger components together. A method of installing such heat exchangers in rotary kilns is also disclosed. Installation is relatively fast and simple, and the heat exchangers are capable of withstanding the harsh operating conditions of rotary kilns for extended periods of time.