Abstract: A refractory composition and processes for manufacture are provided where the compositions possess improved refractory alkali resistance and superior handling properties. Compositions and processes for their manufacture may include a plurality of ceramic particles and a binder sintered to the particles wherein the binder includes crystalline aluminum orthophosphate distributed as the result of an in situ reaction of aluminum metaphosphate with alumina. Kits provided according to the invention provide materials for use in manufacture of a composition where the kit includes aluminum metaphosphate and a nonfacile additive.

Abstract: Refractory compositions and methods of forming articles therefrom are provided that include a plurality of aggregate particles and a binder intermixed with the aggregate particles. The binder composition includes sintered crystalline chromium metaphosphate or chromium-aluminum metaphosphate, or combinations of the two distributed in the binder. The provided compositions are free of chromium oxide yet exhibit excellent slag resistance and are easily disposed of.

Abstract: Refractory compositions and methods of forming articles therefrom are provided that include a plurality of aggregate particles and a binder intermixed with the aggregate particles. The binder composition includes sintered crystalline chromium metaphosphate or chromium-aluminum metaphosphate, or combinations of the two distributed in the binder. The provided compositions are free of chromium oxide yet exhibit excellent slag resistance and are easily disposed of.

Abstract: A refractory composition and processes for manufacture are provided where the compositions possess improved refractory alkali resistance and superior handling properties. Compositions and processes for their manufacture may include a plurality of ceramic particles and a binder sintered to the particles wherein the binder includes crystalline aluminum orthophosphate distributed as the result of an in situ reaction of aluminum metaphosphate with alumina. Kits provided according to the invention provide materials for use in manufacture of a composition where the kit includes aluminum metaphosphate and a nonfacile additive.

Abstract: Processes of forming or repairing a structure used in a high temperature application are provided whereby a refractory article lining that is glazed on a face closest to a structure wall is used to form or replace a portion of the refractory surface in such a structure. The refractory articles may be chemically and/or mechanically bonded to an adhesive mortar capable of chemically reacting with the material used to form the brick to form a high strength, substantially monolithic surface that resists penetration by flux salts dramatically increasing the life of the repair. The process allows for low cost, long lasting repair of structures used in high temperature applications that was previously unrealizable. Also provided are refractory articles with a glaze coating on at least a portion thereof that prevents flux salt penetration. The refractory articles are optionally used in a system along with a complementary adhesive mortar.

Abstract: A refractory structural element is provided that is useful for lining the inner surface of a construct typically used as a kiln or other high temperature system. An element includes a stem portion associated with a flared end block portion whereby the flared end block portion is compatible with other structural elements to form a substantially continuous tiled surface when a plurality of refractory structural elements are laid adjacent to each other. The stem portion optionally has a plurality of protrusions decorated on its outer surface that may serve to adjust heat dissipation from the element.

Abstract: Bonded aggregate compositions such as concrete, concrete repair products, high temperature refractories, high temperature insulation and fire resistant insulation are made from an aqueous solution of phosphoric acid and a separate, storable dry mixture of suitable aggregate, monocalcium phosphate, and calcium in the form of calcium aluminate cement or calcium oxide. The proportion of wet to dry constituents is variable so as to select the working time and strength of the aggregate composition, typically on the order of ten to fifteen minutes. The mixture of the preferred dry constituents, and the binder to be mixed with the aggregate to yield the preferred dry mixture, are also disclosed.

Abstract: Bonded aggregate compositions such as concrete, concrete repair products, high temperature refractories, high temperature insulation and fire resistant insulation are made from an aqueous solution of phosphoric acid and a separate, storable dry mixture of suitable aggregate, monocalcium phosphate, and calcium in the form of calcium aluminate cement or calcium oxide. The proportion of wet to dry constituents is variable so as to select the working time and strength of the aggregate composition, typically on the order of ten to fifteen minutes. The mixture of the preferred dry constituents, and the binder to be mixed with the aggregate to yield the preferred dry mixture, are also disclosed.