Abstract: A method of flame spraying refractory material for in situ repair of, e.g., furnace linings wherein an inert carrier gas incapable of supporting combustion and particles of refractory oxide and combustible metal or other oxidizable material are delivered to a flame spraying apparatus wherein high pressure oxygen aspirates and accelerates the carrier gas-particle mixture; a controlled ratio of 5 to 1 to about 30 to 1 oxygen gas to carrier gas; allows for the use of highly combustible metals and materials such as chromium, aluminum, zirconium, and/or magnesium as heat sources without back-flash and at a deposition rate in excess of 2000 pounds per hour of refractory oxide to yield a deposited refractory mass exhibiting enhanced wear and erosion resistance.

Abstract: A method of increasing the life of tuyere area refractories through repeated application of coherent refractory mass formed by ceramic welding process onto worn area after installing protective removable, expendable or reuseable pipes/rods. Consecutive use of this process can effectively suspend or reduce or control the wear of the original refractories.

Abstract: Oxidizable metallic particles having a grain size of 60 microns or less of the combination of zinc and magnesium used as heat sources in the flame spraying of refractory masses wherein the zinc magnesium form 5% or less by weight of the total mixture of oxidizable particles and refractory particles, and are used with oxidizable metallic silicon in an amount between 8 and 20% by weight, wherein one or more of silica, alumina, magnesite, chromia and/or zirconia, or silicon carbide form the incombustible refractory particles.